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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 217 records · Page 12

Power Electronics Based Self-Monitoring and Diagnosing for Photovoltaic Systems

Faults in photovoltaic (PV) systems can seriously affect the efficiency, energy yield, cost, safety, and reliability of PV plants. Condition monitoring of PV plants is, therefore, a very important approach to estimating the health condition of PV modules and power electronics in the system. However, additional hardware for PV system monitoring adds cost to the system's operation; delayed maintenance service also causes additional energy production loss. The Center for Power Electronics Systems (CPES) at the Virginia Polytechnic Institute and State University and Siemens Cooperate Research developed the online impedance measurement for a PV panel self-monitoring and diagnosing technology using the DC-DC converter connected to the panel. Small-signal impedances of a monocrystalline silicon PV panel were modeled and simulated to reflect fault conditions such as the short-circuit, hot-spot, and junction box faults. Modeling and simulation results were validated firstly using a test setup consisting of a solar simulator, a network analyzer, small-signal injectors, and a monocrystalline PV panel rated at 300 W.

14 SOLAR ENERGY↗

Augmented Monitoring and Condition Assessment Program for SNF Wet Storage Life Extension - 20489

Approximately 27 MTHM of spent nuclear fuel (SNF) owned and managed by the U.S. Department of Energy, Office of Environmental Management is stored in the L Basin at the Savannah River Site (SRS). This 'DOE SNF' is comprised of approximately 12,000 aluminum-clad, aluminum-based fuel assemblies (∼7 MTHM), and approximately 2000 non-aluminum fuel assemblies (∼20 MTHM). A program is in progress to perform Non-Destructive Examination (NDE) of the fuel and their storage containers to characterize the materials' condition, and to evaluate the effects of service to enable continued safe wet storage of the SNF. The Augmented Monitoring and Condition Assessment Program (AMCAP), a two-part program to develop and implement remote underwater Non-Destructive Examination of the aluminum SNF, and of the containers of the non-aluminum SNF, respectively, is aimed at the characterization and evaluation of corrosion degradation of aluminum fuel and container materials. The predominant design of the aluminum SNF (ASNF) stored in L Basin is the Materials Test Reactor (MTR) equivalent design, a plate fuel design. These SNF are stored in 5'' diameter tubes or 5'' x 5'' squares (called bundles) that are nominally 12' or up to 14' long. The SNF is de-bundled and inspected using a custom-designed MTR Fuel Inspection Table. The inspection table provides for indexed fuel positioning for a video camera examination with controlled lighting. A total of 10 of the SNF originating from foreign research and test reactors were selected for examination based on burnup, enrichment, and prior damage caused by service/storage history. A special inspection campaign of these 10 assemblies is in progress. The observed corrosion damage included minor to moderate attack from general corrosion, pitting, crevice, end grain and galvanic corrosion. Example results from the completed inspections are shown and discussed. The focus is a comparison of the as-received condition versus the as-found current storage condition that will serve to validate Water Chemistry and Corrosion Monitoring Programs. The non-aluminum SNF (NASNF) stored in L Basin are of diverse design that includes various geometries with claddings of stainless steel, Zircaloy, and Hastelloy. The fuel core materials include uranium alloys, oxides/mixed oxides, and carbides. These SNF materials, originating from early experimental and test reactors, are in various physical forms including single fuel elements and cut pieces. The fuel is stored in L Basin in various configurations including in direct bundled storage in aluminum tubes and in isolation cans that are in the bundles or in a larger over-size storage container (OSC). Concern with inside-out corrosion and the potential loss of configuration control and ability to handle the storage containers prompted the development of remote NDE methods that include visual and UT technologies to assess the condition of the containers. Candidate stored materials were selected for a special inspection campaign; the development of the NDE methods for the inspection for galvanic, crevice and sediment-induced corrosion (inside-out) are discussed. A summary of the SNF storage in L Basin at the SRS, and an overview of the AMCAP to enable continued safe storage of DOE SNF are described. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

A Comparison of a Brain-Based Adaptive System and a Manual Adaptable System for Invoking Automation

Two experiments are presented that examine alternative methods for invoking automation. In each experiment, participants were asked to perform simultaneously a monitoring task and a resource management task as well as a tracking task that changed between automatic and manual modes. The monitoring task required participants to detect failures of an automated system to correct aberrant conditions under either high or low system reliability. Performance on each task was assessed as well as situation awareness and subjective workload. In the first experiment, half of the participants worked with a brain-based system that used their EEG signals to switch the tracking task between automatic and manual modes. The remaining participants were yoked to participants from the adaptive condition and received the same schedule of mode switches, but their EEG had no effect on the automation. Within each group, half of the participants were assigned to either the low or high reliability monitoring task. In addition, within each combination of automation invocation and system reliability, participants were separated into high and low complacency potential groups. The results revealed no significant effects of automation invocation on the performance measures; however, the high complacency individuals demonstrated better situation awareness when working with the adaptive automation system. The second experiment was the same as the first with one important exception. Automation was invoked manually. Thus, half of the participants pressed a button to invoke automation for 10 s. The remaining participants were yoked to participants from the adaptable condition and received the same schedule of mode switches, but they had no control over the automation. The results showed that participants who could invoke automation performed more poorly on the resource management task and reported higher levels of subjective workload. Further, those who invoked automation more frequently performed more poorly on the tracking task and reported higher levels of subjective workload. and the adaptable condition in the second experiment revealed only one significant difference: the subjective workload was higher in the adaptable condition. Overall, the results show that a brain-based, adaptive automation system may facilitate situation awareness for those individuals who are more complacent toward automation. By contrast, requiring operators to invoke automation manually may have some detrimental impact on performance but does appear to increases subjective workload relative to an adaptive system.

Bailey, Nathan R.↗

Application and Certification of Comparative Vacuum Monitoring Sensors for Structural Health Monitoring of 737 Wing Box Fittings

Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today's extensive fleet of aging aircraft and space vehicles. The use of in-situ sensors for real-time health monitoring of aircraft structures are a viable option to overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. Prevention of unexpected flaw growth and structural failure can be improved if on-board health monitoring systems are used to continuously assess structural integrity. Such systems are able to detect incipient damage before catastrophic failures occurs. Condition-based maintenance practices could be substituted for the current time-based maintenance approach. Other advantages of on-board distributed sensor systems are that they can eliminate costly, and potentially damaging, disassembly, improve sensitivity by producing optimum placement of sensors and decrease maintenance costs by eliminating more time- consuming manual inspections. This report presents a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Boeing, Delta Air Lines, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp. and the Federal Aviation Administration (FAA) carried out a certification program to formally introduce Comparative Vacuum Monitoring (CVM) as a structural health monitoring solution to a specific aircraft wing box application. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM into an airline maintenance program and the document revisions necessary to allow for routine use of CVM as an alternate means of performing periodic structural inspects. To carry out the validation process, knowledge of aircraft maintenance practices was coupled with an unbiased, independent evaluation. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically-relevant experimental effort to quantify the reliability of the CVM system applied to the Boeing 737 Wing Box fitting application. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for CVM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and also is acceptable to both the aviation industry and regulatory bodies. This report presents the use of several different statistical methods, some of them adapted from NDI performance assessments and some proposed to address the unique nature of damage detection via SHM systems, and discusses how they can converge to produce a confident quantification of SHM performance An important element in developing SHM validation processes is a clear understanding of the regulatory measures needed to adopt SHM solutions along with the knowledge of the structural and maintenance characteristics that may impact the operational performance of an SHM system. This report describes the major elements of an SHM validation approach and differentiates the SHM elements from those found in NDI validation. The activities conducted in this program demonstrated the feasibility of routine SHM usage in general and CVM in particular for the application selected. They also helped establish an optimum OEM-airline-regulator process and determined how to safely adopt SHM solutions. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM technology. It will also streamline the regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗

Continued Development of Compact Multi-gas Monitor for Life Support Systems Control in Space

Miniature optic gas sensors (MOGS) based on luminescent materials have shown great potential as alternatives to Near-Infrared-based gas sensor systems for the advanced space suit portable life support system (PLSS). The unique capability of MOGS for carbon dioxide and oxygen monitoring under wet conditions has been reported, as has the fast recovery of MOGS humidity sensors after long periods of being wet. Lower volume and power requirements are also potential advantages of MOGS over both traditional and advanced Non-Dispersive Infrared (NDIR) gas sensors, which have shown so far longer life than luminescent sensors. This paper presents the most recent results in the development and analytical validation of a compact multi-gas sensor unit based on luminescent sensors for the PLSS. Results of extensive testing are presented, including studies conducted at Intelligent Optical Systems laboratories, a United Technology Corporation Aerospace Systems (UTAS) laboratory, and a Johnson Space Center laboratory. The potential of this sensor technology for gas monitoring in PLSSs and other life support systems and the advantages and limitations found through detailed sensor validation are discussed.

Delgado-Alonso, Jesús↗

A New Interferometer for Monitoring Atmospheric Phase Fluctuations

Water vapor in the Earth's troposphere introduces an extra electrical path in the propagation of radio signals through the atmosphere. The distribution of water vapor is irregular and distorts the wavefronts of incoming radio waves, limiting the angular resolution that can be achieved with ground-based telescopes. The level of fluctuations depends both on the location of the site ,and on the prevailing atmospheric conditions. The ability to measure the fluctuations is therefore important when choosing a site for a new instrument, and for scheduling observations of existing telescopes. Existing phase monitors are radio interferometers that monitor monochromatic beacon tones from geostationary communications satellites at a frequency of about 12 GHz. They have a classical heterodyne design based on two satellite receiving antennas; each has a front-end for amplifying and down-converting the incoming signals using a local oscillator that is phase-locked to a common reference frequency. In addition to multiple phase-locked loops these instruments require expensive phase-stable cabling to reduce the effects of thermal drift. The new system uses two consumer 18" digital satellite TV dishes to monitor satellite TV broadcast signals over a bandwidth of 500 MHz (12.2 to 12.7 GHz). The novel design eliminates the need for phase-locked loops and thermally stable components, and uses a pair of Gilbert Cell multipliers to perform the broadband correlation. A phase monitor has been been built and deployed at the site of the Berkeley-Illinois-Maryland Association Millimeter Array in Northern California, and has been operating successfully since June 1998, measuring the difference in electrical path length for parallel lines of sight to the satellite separated by a baseline of 100 m. With a hardware cost of approximately $4000, it is much cheaper than previous instruments, and the low power requirements and high reliability make the system suitable for site testing in remote locations.

Lay, Oliver↗

Probabilistic Voltage Sensitivity based Preemptive Voltage Monitoring in Unbalanced Distribution Networks

With increasing penetration of renewable energy and active consumers, control and management of power distribution networks has become challenging. Renewable energy sources can cause random voltage fluctuations as their output power depends on weather conditions. Conventional voltage control schemes such as tap changers and capacitor banks lack the foresight required to quickly alleviate voltage violations. Thus, there is an urgent need for effective approaches for predicting and mitigating voltage violations as a result of random fluctuations in power injections. This work proposes a novel voltage monitoring approach based on low-complexity, data-driven probabilistic voltage sensitivity analysis. The usefulness of this work is not only in predicting voltage violations in unbalanced distribution grids, but also in opening up the door for optimal voltage control. Using system data and forecasts, the proposed approach predicts the distribution of system node voltages which is then used to to identify nodes that may violate the nominal operational limits with high probability. The method is tested on the IEEE 37 node distribution system considering integrated distributed solar energy sources. The method is validated against the classic load flow based method and offers over 95% accuracy in predicting voltage violations.

Abujubbeh, Mohammad↗

Integrated Laser Characterization, Data Acquisition, and Command and Control Test System

Satellite-based laser technology has been developed for topographical measurements of the Earth and of other planets. Lasers for such missions must be highly efficient and stable over long periods in the temperature variations of orbit. In this innovation, LabVIEW is used on an Apple Macintosh to acquire and analyze images of the laser beam as it exits the laser cavity to evaluate the laser s performance over time, and to monitor and control the environmental conditions under which the laser is tested. One computer attached to multiple cameras and instruments running LabVIEW-based software replaces a conglomeration of computers and software packages, saving hours in maintenance and data analysis, and making very longterm tests possible. This all-in-one system was written primarily using LabVIEW for Mac OS X, which allows the combining of data from multiple RS-232, USB, and Ethernet instruments for comprehensive laser analysis and control. The system acquires data from CCDs (charge coupled devices), power meters, thermistors, and oscilloscopes over a controllable period of time. This data is saved to an html file that can be accessed later from a variety of data analysis programs. Also, through the LabVIEW interface, engineers can easily control laser input parameters such as current, pulse width, chiller temperature, and repetition rates. All of these parameters can be adapted and cycled over a period of time.

Stysley, Paul↗

High Precision, Absolute Total Column Ozone Measurements from the Pandora Spectrometer System: Comparisons with Data from a Brewer Double Monochromator and Aura OMI

We present new, high precision, high temporal resolution measurements of total column ozone (TCO) amounts derived from ground-based direct-sun irradiance measurements using our recently deployed Pandora single-grating spectrometers. Pandora's small size and portability allow deployment at multiple sites within an urban air-shed and development of a ground-based monitoring network for studying small-scale atmospheric dynamics, spatial heterogeneities in trace gas distribution, local pollution conditions, photochemical processes and interdependencies of ozone and its major precursors. Results are shown for four mid- to high-latitude sites where different Pandora instruments were used. Comparisons with a well calibrated double-grating Brewer spectrometer over a period of more than a year in Greenbelt MD showed excellent agreement and a small bias of approximately 2 DU (or, 0.6%). This was constant with slant column ozone amount over the full range of observed solar zenith angles (15-80), indicating adequate Pandora stray light correction. A small (1-2%) seasonal difference was found, consistent with sensitivity studies showing that the Pandora spectral fitting TCO retrieval has a temperature dependence of 1% per 3K, with an underestimation in temperature (e.g., during summer) resulting in an underestimation of TCO. Pandora agreed well with Aura-OMI (Ozone Measuring Instrument) satellite data, with average residuals of <1% at the different sites when the OMI view was within 50 km from the Pandora location and OMI-measured cloud fraction was <0.2. The frequent and continuous measurements by Pandora revealed significant short-term (hourly) temporal changes in TCO, not possible to capture by sun-synchronous satellites, such as OMI, alone.

Ozone↗

Satellite Gravimetry Improves Seasonal Streamflow Forecast Initialization in Africa

West Africa is one of the poorest regions in the world and highly vulnerable to extreme hydrological events due to the lack of reliable monitoring and forecast systems. For the first time, we demonstrate that initial hydrological conditions informed by satellite-based terrestrial water storage (TWS) estimates improve seasonal streamflow forecasts. TWS variability detected by the Gravity Recovery and Climate Experiment (GRACE) satellites is assimilated into a land surface model during 2003–2016 and used to initialize 6-month hindcasts (i.e., forecasts of past events) during West Africa's wet seasons. We find that GRACE data assimilation (DA) generally increases groundwater and soil moisture storage in the region, resulting in increased evapotranspiration and reduced total runoff. Total runoff is particularly lower at the headwaters of the Niger River, positively impacting streamflow simulations and hindcast initializations. Compared to simulations without GRACE-DA, hindcasts are notably improved at locations draining from large basin areas, in particular, over the Niger River basin, which is consistent with GRACE's coarse spatial resolution. The long memory of groundwater and deep soil moisture, two main TWS components updated by GRACE-DA, is reflected in prolonged improvements in the streamflow hindcasts. Model accuracy at Niamey, Niger, the most populated city where streamflow observations are available, improved up to 33% during the flood season. These new findings directly contribute to ongoing developments in food security, flood potential forecast, and water-related disaster warning systems for Africa.

Augusto Getirana↗

Physics-Guided Deep Learning for Complex System Health Management and Decision Making

The landscape of complex engineered systems is rapidly evolving, from smart manufacturing facilities to next-generation transportation vehicles. As these systems become increasingly sophisticated and interconnected, the need for advanced health management systems grows ever more critical. These systems must go beyond simple monitoring, actively predicting potential failures before they occur. This paradigm shift from fixed maintenance schedules to condition-based predictions is key to optimizing system performance, enhancing safety, and paving the way for autonomous decision-making across various industries. Whether in industrial processes, energy systems, or advanced transportation, the ability to anticipate and prevent failures is becoming a cornerstone of operational excellence. To accurately predict the future health of any complex system, knowledge of its current health state and future operational conditions is essential. Recent advancements in data-driven algorithms have generated growing interest in artificial intelligence for industrial applications. However, the limitations of pure data-driven methods, particularly in industries where data acquisition is costly and limited, have become apparent. This has led to a focus on blending physics with data-driven algorithms, mitigating the drawbacks of both approaches while emphasizing their respective advantages. This research proposes a novel framework for integrating physics-based performance models with deep learning algorithms for the prognostics of complex safety-critical systems. In this approach, physics-based models serve as a blueprint, capturing fundamental system behaviors, while deep learning algorithms, leveraging real-world sensor data, fill in gaps and identify subtle patterns indicative of potential problems. This hybrid methodology, utilizing techniques such as Physics-Informed Neural Networks (PINNs), offers a powerful solution for predicting system health. By fusing domain knowledge with data-driven insights, this approach promises more accurate, adaptable, and reliable models for health prediction. The resulting framework is versatile, applicable across various sectors including aerospace, manufacturing, and energy systems, ultimately contributing to safer, more efficient operations in our increasingly complex technological landscape.

Diagnostics↗

Artificial Intelligence and Computer Vision for Cost-Effective Benthic Habitat Characterizations

Machine learning applied to computer vision and pattern recognition is a type of artificial intelligence that has advanced rapidly in the last 10 to 15 years, spurred forward by breakthroughs in deep convolutional neural networks. These state-of-the-art methods are poised to become widely used in environmental monitoring applications as a result of the increasing abundance of data available from different imaging platforms (e.g., fixed-point cameras, drone surveys, high-resolution satellite data) that can be analyzed to observe, model, and understand environmental conditions. Computer vision and pattern recognition (CVPR) tools advance our ability to use imagery and camera-based tools in cost-effective ways for environmental monitoring. Although these techniques offer great potential, some challenges remain, such as the need for large sets of labeled images for model training and validation and optimized hardware and software to ensure that the models can be trained effectively and in a reasonable amount of time. Here, we have overcome many of these rate-limiting challenges by using a diverse image library built across multiple projects coupled with staff expertise and onsite computing resources. We are working toward a fully automated SPI processing system and also are moving to develop CVPR analytical tools for other imaging platforms and data sets.

02 PETROLEUM↗

The Viking parachute qualification test technique.

The parachute system for NASA's Viking '75 Mars lander was flight qualified in four high-altitude flight tests at the White Sands Missile range (WSMR). A balloon system lifted a full-scale simulated Viking spacecraft to an altitude where a varying number of rocket motors were used to propel the high drag, lifting test vehicle to test conditions which would simulate the range of entry conditions expected at Mars. A ground-commanded cold gas pointing system located on the balloon system provided powered vehicle azimuth control to insure that the flight trajectory remained within the WSMR boundaries. A unique ground-based computer-radar system was employed to monitor inflight performance of the powered vehicle and insure that command ignition of the parachute mortar occurred at the required test conditions of Mach number and dynamic pressure. Performance data were obtained from cameras, telemetry, and radar.

Raper, J. L.↗

Western Sonoran Desert Water Resources: Evaluating Rock Pool Hydroperiod Fluctuation using Climate Variables to Inform Habitat Monitoring and Protection in the Western Sonoran Desert

Ephemeral freshwater rock pools, known as tinajas, have great biologic and cultural importance as sources of surface water in the western Sonoran Desert (WSD). Tinaja flooding and drying cycles, known as hydroperiods, vary based on meteorologic and climatologic conditions; however, a lack of extensive research relating climatic impacts to tinajas puts these critical ecosystems further at risk. The National Park Service (NPS) and the University of Arizona monitor the physical and ecological condition of tinajas in Organ Pipe Cactus National Monument (OPCNM), AZ, using resource-intensive strategies: in situ trail cameras and direct measurements. To aid monitoring efforts, the NASA DEVELOP team aimed to incorporate remote sensing into NPS strategies by analyzing spatiotemporal climate data and tinaja hydroperiods in OPCNM between 1979–2022. Using Aqua and Terra Moderate Resolution Imaging Spectroradiometers (MODIS), University of Idaho Gridded Surface Meteorological Dataset (gridMET), and OpenET data, the team generated climatology maps and time series for OPCNM. The team compared these data to daily in situ hydroperiod observations from the University of Arizona between 2019–2022. Climate maps and time series showed increases in temperature and solar radiation (p<0.05), while analyses of in situ data showed correlations of hydroperiods with precipitation and evapotranspiration. End products identified high-risk tinajas and demonstrated that Earth observations can successfully be correlated with in situ hydroperiod observations. These results will support NPS efforts to prioritize water resource management and inform protocols driving the conservation of tinajas in OPCNM.

Anne Britton↗

Addressing Control Research Issues Leading to Piloted Simulations in Support of the IFCS F-15

This report summarizes the research effort by a team of researchers at West Virginia University in support of the NASA Intelligent Flight Control System (IFCS) F-15 program. In particular, WVU researchers assisted NASA Dryden researchers in the following technical tasks leading to piloted simulation of the 'Gen_2' IFCS control laws. Task #1- Performance comparison of different neural network (NN) augmentation for the Dynamic Inversion (DI) -based VCAS 'Gen_2' control laws. Task #2- Development of safety monitor criteria for transition to research control laws with and without failure during flight test. Task #3- Fine-tuning of the 'Gen_2' control laws for cross-coupling reduction at post-failure conditions. Matlab/Simulink-based simulation codes were provided to the technical monitor on a regular basis throughout the duration of the project. Additional deliverables for the project were Power Point-based slides prepared for different project meetings. This document provides a description of the methodology and discusses the general conclusions from the simulation results.

Napolitano, Marcello↗

Visual Attention Allocation Between Robotic Arm and Environmental Process Control: Validating the STOM Task Switching Model

Fifty six participants time shared a spacecraft environmental control system task with a realistic space robotic arm control task in either a manual or highly automated version. The former could suffer minor failures, whose diagnosis and repair were supported by a decision aid. At the end of the experiment this decision aid unexpectedly failed. We measured visual attention allocation and switching between the two tasks, in each of the eight conditions formed by manual-automated arm X expected-unexpected failure X monitoring- failure management. We also used our multi-attribute task switching model, based on task attributes of priority interest, difficulty and salience that were self-rated by participants, to predict allocation. An un-weighted model based on attributes of difficulty, interest and salience accounted for 96 percent of the task allocation variance across the 8 different conditions. Task difficulty served as an attractor, with more difficult tasks increasing the tendency to stay on task.

STOM attention allocation model validation↗

Hand-held radiometer red and photographic infrared spectral measurements of agricultural crops

Red and photographic infrared radiance data, collected under a variety of conditions at weekly intervals throughout the growing season using a hand-held radiometer, were used to monitor crop growth and development. The vegetation index transformation was used to effectively compensate for the different irradiational conditions encountered during the study period. These data, plotted against time, compared the different crops measured by comparing their green leaf biomass dynamics. This approach, based entirely upon spectral inputs, closely monitors crop growth and development and indicates the promise of ground-based hand-held radiometer measurements of crops.

Tucker, C. J.↗

Developing NDE Techniques for Large Cryogenic Tanks - Year 2 Report

The Shuttle Program requires very large cryogenic ground storage tanks in which to store liquid oxygen and hydrogen. The existing Launch Complex-39 Pad tanks, which will be passed onto future launch programs, are over 40 years old and have received minimal refurbishment and only external inspections over the years. The majority of the structure is inaccessible without a full system drain of cryogenic liquid and insulation in the annular region. It was previously thought that there was a limit to the number of temperature cycles that the tanks could handle due to possible insulation compaction before undergoing a costly and time consuming complete overhaul; therefore the tanks were not drained and performance issues with these tanks, specifically the Pad B LH2 tank, were accepted. There is a need and an opportunity, as the Shuttle program ends and work to upgrade the launch pad progresses, to develop innovative non-destructive evaluation (NDE) techniques to analyze the current tanks. Techniques are desired that can aid in determining the extent of refurbishment required to keep the tanks in service for another 20+ years. A non-destructive technique would also be a significant aid in acceptance testing of new and refurbished tanks, saving significant time and money, if corrective actions can be taken before cryogen is introduced to the systems. Year one of this project concentrated on analysis of the current tanks located at LC-39 while cryogen was present. Year two of this project concentrated on analysis of detectable thermal variations on the outer surface of the tanks as the cryogen was drained and the inner vessel warmed to ambient conditions. Two techniques have been deployed in the field to monitor the tank. The first consisted of a displacement sensor to monitor for any expansions at the base of the tank during warm-up that could indicate a compaction issue with the insulation. The second technique was continued thermal monitoring of the tank through and after warm up. The indications noted in the thermal images were compared to bore-scope images of the annular region taken once the tank was inert and warmed to ambient conditions. Similar thermal imaging was performed on a smaller tank where an insulation void was induced to compare the effectiveness of thermal imagining on a different tank geometry.

Arens, Ellen↗