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DOE OSTI2024

Report on Initial Sodium Testing on the Thermal Hydraulic Experimental Test Article (THETA) (Fiscal Year 2024 Final Report)

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that is used to develop sodium components and instrumentation as well as to acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility simulates nominal thermal hydraulic conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field may be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility was designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary coolant and secondary coolant system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. In fiscal year 2023, thermal stratification tests were completed with the primary system online, while the secondary system was being constructed [1]. These tests had shown that the core barrel and intermediate heat exchanger (IHX) outlet required increased thermal insulation. The THETA primary system was removed from METL, cleaned, thermal insulators installed, and then inserted into METL Test Vessel 4. At the time of this writing the THETA primary and secondary system are operational. During this fiscal year 100+ hours of testing was completed to characterize thermal hydraulic phenomena associated with steady state and transient conditions in a pool type liquid metal cooled reactor. A majority of the testing campaign was completed to satisfy the experimental data acquisition requirements for the GAIN Voucher with Oklo, CRADA 2021-21121. THETA is still operational at the time of this publication and future testing is planned for fiscal year 2025. Work is underway to publish existing and future data to an online database to facilitate collaboration with SFR engineers looking to validate their systems code or computational fluid dynamics models.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Development of a Test-Bed for Testing and Refining EarthEn’s Supercritical CO 2 Based Energy Storage System

EarthEn’s energy storage concept leverages supercritical carbon dioxide (sCO 2 ) as a working fluid and relies on compact, high-performance components operating at elevated pressures and temperatures. To accelerate component development and reduce technical risk prior to larger-scale demonstrations, Oak Ridge National Laboratory (ORNL) developed a 100 kW-scale sCO 2 test-bed under a Cooperative Research and Development Agreement with EarthEn (CRADA NO. NFE-24-10050). The objective of the work was to design and construct a flexible experimental facility capable of reproducing key thermodynamic state points and heat-transfer conditions relevant to EarthEn’s thermal energy storage (TES) cycle, with particular emphasis on enabling development and evaluation of next-generation heat exchangers and TES concepts. The test-bed consists of a closed-loop sCO 2 circulation system housed within an open-topped enclosure. In its as-installed configuration, dense-phase sCO 2 is recirculated through a printed circuit recuperator, an electrically heated section, a throttling device used to simulate turbine expansion, and a water-cooled printed circuit heat exchanger that rejects heat to the building chilled-water system before returning to the pump. The pump is driven by a variable frequency drive, enabling controlled adjustment of flow and operating point. A comprehensive instrumentation suite was integrated to support both safe operation and high-quality data collection. Installed sensors include Coriolis flow meters for sCO 2 flow rate and density, resistance temperature detectors and thermocouples distributed throughout the loop (including the heated section and key heat exchanger ports), and pressure transducers for absolute and differential pressure measurements. The facility was designed to support high-pressure (19 MPa nominal) and high-temperature (575°C nominal) operation with credited overpressure protection provided by a rupture disk. Nominal operating conditions were selected to support 100 kW-class testing while maintaining flexibility for non-heated and heated shakedown, control development, and future integration of advanced TES test sections. In parallel with facility development, a system-level thermal-hydraulic model was created using Modelica-based tools to support component sizing, anticipate performance over targeted test conditions, and establish a framework for future model calibration against experimental data. At the conclusion of the project performance period, the facility was in final assembly, and the pressure boundary was nearly completed. However, several practical challenges associated with high-pressure/high-temperature systems and specialized component procurement impacted schedule and prevented initial pump-driven operation and full commissioning within the available resources. This report documents the as-built design, operating capabilities, and instrumentation, and it summarizes key lessons learned related to heater fabrication and testing, first-of-a-kind assembly factors, specialty flange supply constraints, and fill pump corrective actions. Finally, it outlines a phased plan for future commissioning and experimental campaigns, including control and instrumentation shakedown, heater characterization, model calibration, and testing at state points representative of EarthEn’s TES cycle.

25 ENERGY STORAGE↗

DOE OSTI2023

Geomechanical in situ testing of fault reactivation in argillite repositories

Abstract. Pressurization of natural faults as a result of repository-induced effects can lead to their reactivation and permeability generation in case such features are present near disposal tunnels. Potential driving forces for such pressurization are the temperature increase caused by heat-producing high-level radioactive waste and the generation of hydrogen and other gases due to corrosion of engineered materials. We are primarily concerned about pressurization and fault activation in host rocks and faults that have very low natural permeability for pore pressure increases to dissipate, such as the argillite rocks currently investigated in Switzerland, France and other countries. This presentation discusses a series of in situ experiments of fault activation by fluid injection conducted in the argillite rock (Opalinus clay) at the Mont Terri underground research laboratory in Switzerland. A multi-model monitoring test bed was installed at Mont Terri that includes distributed fiber optics for strain, temperature, and acoustics; local fault pore pressure and three-dimensional displacement sensors; active seismic imaging; and passive seismic monitoring. The fault experiments (and their subsequent analysis via hydromechanical modeling) provide a new fundamental understanding of the coupling between pore pressure, fault deformation and permeability generation as a function of time and allow exploring how seismic and aseismic events may impact the integrity of faulted argillite host rock. Our experimental observations demonstrate that significant flow (and transport) can occur along the initially impermeable argillite fault when rupture is activated. However, the fault permeability decreases to almost its pre-activation value when fluid injection ceases and fluid pressure drops. Dilatant slip on the fault plane alone does not explain the observed increase in fault permeability; pressure-induced fault opening also plays a role, favored by the softness of the shale along with the fact that the structure of the fault zone prevents fluids from diffusing into the adjacent damage zone. Rupture initiation and permeability generation is initially aseismic, associated only with an increase in noise level and emerging tremors. Micro-earthquakes are initiated later in the experiments and typically occur away from the fluid-pressurized area. Hydromechanical models show that stress transferred from the initial aseismic deformation can build up to stress criticality and later induce seismic rupture. After presenting the experimental results, we will close the presentation with an outlook to future experimental campaigns using the fault test bed at Mont Terri. We are currently planning a controlled thermal stimulation of the fault, where instead of fluid injection as a trigger mechanism we will heat up the nearby rock volume and measure potential effects on fault stability. Lessons learned from our past and future experiments will help inform the safety assessment of geologic disposal in argillite host rock.

Birkholzer, Jens T.↗

NASA NTRS1977

A preliminary investigation of the Environmental Control and Life Support Subsystem (EC/LSS) for the space construction base manufacturing modules

The preliminary data of the environmental control and life support subsystem for a space construction base manufacturing module was reported. A space processing module, which is capable of performing production biological experiments, was chosen as a baseline configuration. The primary assemblies and components considered for use were humidity and temperature control, ventilation fan, cabin fan, water separator, condensate storage, overboard dumping, distribution system, contaminant monitoring, cabin sensors, and fire and smoke detection.

Wells, H. B.↗

NASA NTRS1981

Commercial applications of satellite oceanography

It is shown that in the next decade the oceans' commercial users will require an operational oceanographic satellite system or systems capable of maximizing real-time coverage over all ocean areas. Seasat studies suggest that three spacecraft are required to achieve this. Here, the sensor suite would measure surface winds, wave heights (and spectral energy distribution), ice characteristics, sea-surface temperature, ocean colorimetry, height of the geoid, salinity, and subsurface thermal structure. The importance of oceanographic data being distributed to commercial users within two hours of observation time is stressed. Also emphasized is the importance of creating a responsive oceanographic satellite data archive. An estimate of the potential dollar benefits of such an operational oceanographic satellite system is given.

Montgomery, D. R.↗

NASA NTRS1987

Numerical study of the effects of boundary conditions on the measurement and calibration of gardon type heat flux sensors

To monitor the high-intensity heat flux conditions that occur in the space shuttle main engine (SSME), it is necessary to use specifically designed heat flux sensors. These sensors, which are of the Gardon-type, are exposed on the measuring face to high-intensity radiative and convective heat fluxes and on the other face to convective cooling. To improve the calibration and measurement accuracy of these gauges, researchers are studing the effect that the thermal boundary conditions have on gauge performance. In particular, they are studying how convective cooling effects the field inside the sensor and the measured heat flux. The first phase of this study involves a numerical study of these effects. Subsequent phases will involve experimental verification. A computer model of the heat transfer around a Garden-type heat flux sensor was developed. Two specific geometries are being considered are: (1) heat flux sensor mounted on a flat-plate; and (2) heat flux sensor mounted at the stagnation point of a circular cylinder. Both of these configurations are representative of the use of heat flux sensors in the components of the SSME. The purpose of the analysis is to obtain a temperature distribution as a function of the boundary conditions.

Krane, M.↗

NASA NTRS2014

High Sensitivity Stress Sensor Based on Hybrid Materials

A sensing device is used to detect the spatial distributions of stresses applied by physical contact with the surface of the sensor or induced by pressure, temperature gradients, and surface absorption. The sensor comprises a hybrid active layer that includes luminophores doped in a polymeric or organic host, altogether embedded in a matrix. Under an electrical bias, the sensor simultaneously converts stresses into electrical and optical signals. Among many applications, the device may be used for tactile sensing and biometric imaging.

Cao, Xian-An↗

NASA NTRS1992

Aerothermal test results from the second flight of the Pegasus booster

A survey of temperature, heat-flux, and pressure measurements was obtained at speeds through Mach 8.0 on the second flight of the Pegasus air-launched space booster system. All sensors were distributed on the wing-body fairing or fillet. Sensors included thin foil-gauge thermocouples installed near the surface within the thermal protection system. Thermocouples were also installed on the surface of nonablating plugs. The resulting temperature time history allowed derivation of convective heat flux. In addition, commercially available calorimeters were installed on the fillet at selected locations. Calorimeters exhibited a larger change in measured heat flux than collocated nonablating plugs in response to particular events. Similar proportional variations in heat flux across different regions of the fillet were detected by both the calorimeters and nonablating plugs. Pressure ports were installed on some nonablating plugs to explore the effects of port protrusion and high-frequency noise on pressure requirements. The effect of port protrusion on static-pressure measurements was found to decrease with increasing Mach number. High-frequency noise suppression was found to be desirable but not required on any future flight.

Noffz, Gregory K.↗

DOE OSTI2019

High-temperature strain monitoring of stainless steel using fiber optics embedded in ultrasonically consolidated nickel layers

Fiber optic sensors have long been considered for use in structural health monitoring of components because of their small size, high accuracy, and their ability to perform spatially distributed strain measurements when embedded within a component or on its surface. The typical method for transferring strain from the component to the fiber is to use an epoxy, which may not survive extended exposure to high temperatures, thus necessitating a more elaborate technique to embed the fibers. This work represents a first step towards using additive manufacturing techniques to embed fiber optic sensors on stainless steel components for high-temperature strain monitoring, including quantification of the differential thermal strains that develop between the fiber and the steel substrate. Copper-coated optical fibers were embedded in nickel layers on top of a stainless steel substrate using an ultrasonic additive manufacturing technique. The embedded fibers showed minimal signal attenuation and clear compressive strain after embedding. Heating the embedded fibers in steps to temperatures of 300 °C–400 °C resulted in measured strains with values between the expected thermal strain in stainless steel and nickel. Finite element simulations confirm the measured strain values and show that the thermal strain depends on the thickness of the nickel layers deposited on top of the stainless steel substrate. While the fibers failed before reaching temperatures of 500 °C, it is suspected that these failures occurred due to a combination of (1) the lack of strain relief, (2) the high-temperature oxidation of the fiber's copper coating, and (3) improper sizing of the machined channel in which the fiber is placed prior to embedding. If proper coating selection and sizing of the channel can prevent the failures observed in this work, the next step would be to monitor strain during mechanical loading at high temperatures.

36 MATERIALS SCIENCE↗

NASA NTRS1992

Determination of mean rainfall from the Special Sensor Microwave/Imager (SSM/I) using a mixed lognormal distribution

Global estimates of monthly, seasonal, and annual oceanic rainfall are computed for a period of one year using data from the Special Sensor Microwave/Imager (SSM/I). Instantaneous rainfall estimates are derived from brightness temperature values obtained from the satellite data using the Hughes D-matrix algorithm. The instantaneous rainfall estimates are stored in 1 deg square bins over the global oceans for each month. A mixed probability distribution combining a lognormal distribution describing the positive rainfall values and a spike at zero describing the observations indicating no rainfall is used to compute mean values. The resulting data for the period of interest are fitted to a lognormal distribution by using a maximum-likelihood. Mean values are computed for the mixed distribution and qualitative comparisons with published historical results as well as quantitative comparisons with corresponding in situ raingage data are performed.

Berg, Wesley↗

DOE OSTI2023

LiG Metrology, Correlated Error, and the Integrity of the Global Surface Air-Temperature Record

The published 95% uncertainty of the global surface air-temperature anomaly (GSATA) record through 1980 is impossibly less than the 2σ = ±0.25 °C lower limit of laboratory resolution of 1 °C/division liquid-in-glass (LiG) thermometers. The ~0.7 °C/century Joule-drift of lead- and soft-glass thermometer bulbs renders unreliable the entire historical air-temperature record through the 19th century. A circa 1900 Baudin meteorological spirit thermometer bulb exhibited intense Pb X-ray emission lines (10.55, 12.66, and 14.76 keV). Uncorrected LiG thermometer non-linearity leaves 1σ = ±0.27 °C uncertainty in land-surface air temperatures prior to 1981. The 2σ = ±0.43 °C from LiG resolution and non-linearity obscures most of the 20th century GSATA trend. Systematic sensor-measurement errors are highly pair-wise correlated, possibly across hundreds of km. Non-normal distributions of bucket and engine-intake difference SSTs disconfirm the assumption of random measurement error. Semivariogram analysis of ship SST measurements yields half the error difference mean, ±½Δε 1,2, not the error mean. Transfer-function adjustment following a change of land station air-temperature sensor eliminates measurement independence and forward-propagates the antecedent uncertainty. LiG resolution limits, non-linearity, and sensor field calibrations yield GSATA mean ±2σ RMS uncertainties of, 1900–1945, ±1.7 °C; 1946–1980, ±2.1 °C; 1981–2004, ±2.0 °C; and 2005–2010, ±1.6 °C. Finally, the 20th century (1900–1999) GSATA, 0.74 ± 1.94 °C, does not convey any information about rate or magnitude of temperature change.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2013

Characterization of the supersonic flowing microwave discharge using two dimensional plasma tomography

A tomographic numerical method based on the two-dimensional Radon formula for a cylindrical cavity has been employed for obtaining spatial distributions of the argon excited levels. The spectroscopy measurements were taken at different positions and directions to observe populations of excited species in the plasmoid region and the corresponding excitation temperatures. Excited argon states are concentrated near the tube walls, thus, confirming the assumption that the post discharge plasma is dominantly sustained by travelling surface wave. An automated optical measurement system has been developed for reconstruction of local plasma parameters of the plasmoid structure formed in an argon supersonic flowing microwave discharge. The system carries out angle and distance measurements using a rotating, flat mirror, as well as two high precision stepper motors operated by a microcontroller-based system and several sensors for precise feedback control.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS2000

On the Feasibility of Studying Shortwave Aerosol Radiative Forcing of Climate Using Dual-Wavelength Aerosol Backscatter Lidar

The current low confidence in the estimates of aerosol-induced perturbations of Earth's radiation balance is caused by the highly non-uniform compositional, spatial and temporal distributions of tropospheric aerosols on a global scale owing to their heterogeneous sources and short lifetimes. Nevertheless, recent studies have shown that the inclusion of aerosol effects in climate model calculations can improve agreement with observed spatial and temporal temperature distributions. In light of the short lifetimes of aerosols, determination of their global distribution with space-borne sensors seems to be a necessary approach. Until recently, satellite measurements of tropospheric aerosols have been approximate and did not provide the full set of information required to determine their radiative effects. With the advent of active aerosol remote sensing from space (e.g., PICASSO-CENA), the applicability fo lidar-derived aerosol 180 deg -backscatter data to radiative flux calculations and hence studies of aerosol effects on climate needs to be investigated.

Redemann, Jens↗

NASA NTRS2016

Technical Capability Upgrades to the NASA Langley Research Center 8 ft. by 15 ft. Thermal Vacuum Chamber

The 8 ft. by 15 ft. thermal vacuum chamber (TVAC), housed in Building 1250 at the NASA Langley Research Center (LaRC), and managed by the Systems Integration and Test Branch within the Engineering Directorate, has undergone several significant modifications to increase testing capability, safety, and quality of measurements of articles under environmental test. Significant modifications include: a new nitrogen distribution manifold for supplying the shroud and other cold surfaces to liquid nitrogen temperatures; a new power supply and distribution system for accurately controlling a quartz IR lamp suite; a suite of contamination monitoring sensors for outgassing measurements and species identification; a new test article support system; signal and power feed-throughs; elimination of unnecessary penetrations; and a new data acquisition and control commanding system including safety interlocks. This paper will provide a general overview of the LaRC 8 ft. by 15 ft. TVAC chamber, an overview of the new technical capabilities, and will illustrate each upgrade in detail, in terms of mechanical design and predicted performance. Additionally, an overview of the scope of tests currently being performed in the chamber will be documented, and sensor plots from tests will be provided to show chamber temperature and pressure performance with actual flight hardware under test.

Thornblom, Mark N.↗

DOE OSTI2024

Calcined Polyethyleneimine-Coated Optical Fibers for Distributed pH Monitoring at High Pressures and Temperatures

In the oil and gas, CO2 sequestration, H2 subsurface storage, and geothermal energy sectors, subsurface pH measurements are critical for monitoring the geochemical conditions and estimating potential corrosion rates of wellbore systems. Real-time pH measurements in these conditions are vital for detecting and predicting corrosion deterioration of wellbore components that may jeopardize the safety and continued operation of wellbore systems. Previous tests using metal oxide-based coatings (TiO2) provided strong responses at elevated temperatures and moderate pressure stability but provided poor differentiation between acidic and alkaline solutions. Building off the pH responsiveness of the TiO2 surface and known pH sensitivity of amine-based polymers, a coating based on the secondary amine polymer polyethyleneimine (PEI) was developed. As the polymer itself is highly water soluble and easily removed by aqueous solutions, the sensor coating was treated with a high temperature (500 °C) calcination procedure in air to convert it into a more stable oxidized coating capable of withstanding hot aqueous solutions without dissolving while retaining linear pH sensitivity from pH values between 2 and 11. The sensor performance was measured using optical transmission measurements in solutions of various pHs and using optical backscatter reflectometry for distributed pH sensing demonstration in wellbore-relevant pressures (up to 1,000 psi) and temperatures (80 °C).

Shumski, Alexander↗

DOE OSTI2022

Massively distributed fiber strain sensing using Brillouin lasing

Brillouin based distributed fiber sensors present a unique set of characteristics amongst fiber sensing architectures. They are able to measure absolute strain and temperature over long distances, with high spatial resolution, and very large dynamic range in off-the-shelf fiber. However, Brillouin sensors traditionally provide only modest sensitivity due to the weak dependence of the Brillouin frequency on strain and the high signal to noise ratio required to identify the resonance’s peak frequency to within a small fraction of its linewidth. Recently, we introduced a technique which substantially improves the precision of Brillouin fiber sensors by exciting a series of lasing modes in a fiber loop cavity that experience Brillouin amplification at discrete locations in the fiber. The narrow-linewidth and high intensity of the lasing modes enabled ultra-low noise Brillouin sensors with large dynamic range. However, our initial demonstration was only modestly distributed: measuring strain at 40, non-contiguous positions along a 400 m fiber. In this work, we greatly extend this methodology to enable fully distributed sensing at 1000 contiguous locations along 3.5 km of fiber—an order of magnitude increase in sensor count and range. This highly-multiplexed Brillouin fiber laser sensor provides a strain noise as low as 34 nɛ/√Hz and we analyze the limiting factors in this approach.

47 OTHER INSTRUMENTATION↗

DOE OSTI2021

Identification of High-Frequency Transverse Acoustic Modes in Multi-Nozzle Can Combustors

Abstract High frequency thermoacoustic instabilities are problematic for lean-premixed gas turbines. Identifying which acoustic mode is being excited is important, in that it provides insight into potential mitigation measures and mechanical stress/life. However, the frequency spacing between modes becomes quite close for high frequency instabilities in a can combustor. This makes it difficult to distinguish between the modes (e.g., the first transverse mode vs. a higher order axial/mixed mode) based upon frequency calculations alone, which inevitably have uncertainties in boundary conditions, temperature profiles, and combustion response. This paper presents a methodology to simultaneously identify the acoustic mode shapes in the axial and azimuthal directions from acoustic pressure measurements. Multiple high temperature pressure transducers, located at distinct axial and azimuthal positions, are flush mounted in the combustor wall. The measured pressure oscillations from each sensor are then used to reconstruct the pressure distributions by using a least squares method in conjunction with a solution of a three dimensional wave equation. In order to validate the methodology, finite element method (FEM) calculations with estimated post-flame temperature is used to provide the candidate frequencies and corresponding mode shapes. The results demonstrate the reconstructed mode shapes and standing/spinning character of transverse waves, as well as the associated frequencies, both of which are consistent with the FEM predictions. Nodal line location was also extracted from the experimental data during the instabilities in the pressure data.

Kim, J.↗

DOE OSTI2024

All-digital Sensor System for Distributed Downhole Pressure Monitoring in Unconventional Fields

This project developed and validated (through field tests) a new low-cost all-digital pressure sensing technology for in situ distributed downhole pressure monitoring in unconventional oil and gas (UOG) fields. The all-digital sensing technology uses a built-in non-electric analog-to-digital converter (ADC) to transform the pressure information into a combination of binary (ON/OFF) states. As such, the system does not need downhole electronics for signal conditioning and telemetry. The all-digital sensors can be remotely logged over a long distance, and many sensors can be multiplexed for distributed sensing. Based on a review of unconventional wells in the Lower 48 states, the specification of the sensor is to measure pressure up to 69 MPa (10,000 psi) and temperature up to 250°C. A sensor with a helical bourdon sensing element and a digital signal decoder of 50 mm diameter and 109 mm length was constructed. The helical bourdon sensing element was made of 304L stainless steel and filled with motor oil. The digital converter was made up of 8 digital reading pads constructed of high-temperature epoxy with conductive inserts made of stainless steel. The sensor had a linear response to pressure with an accuracy of 0.14 MPa (20 psi). To withstand the high pressure, the sensor was enclosed in a stainless-steel pressure housing with a wall thickness of 5.5 mm, a diameter of 73 mm, and a length of 724 mm. In the laboratory tests, the sensor exhibited no temperature-related effects on the results. The sensor did not show drift over a 14-day test period at elevated pressure. A field test was conducted where the sensor was deployed in a test wellbore at the Quest drilling test facility to a depth of 0 feet over three weeks. The sensor was attached to the production rods, along with a downhole reference sensor of PPS27 type, which is a permanent downhole monitoring system. During the testing phase, the test well annular blow-out preventer was closed, and the well was pressurized at the surface to 11 MPa (1600 psi). The sensor read the elevated bottom hole pressure of 1500 psi. A multiplexing unit was created for the sensor to deploy multiple sensors on one data transmission line in a distributed approach. The multiplexing unit was tested in a simulated environment of 3048 m (10,000 ft) with five sensors distributed. The sensors were pressurized at different intervals. The multiplexed sensors recorded the correct pressure, and the multiplexing did not interfere with the readings. The proposed concept of an all-digital pressure sensor for harsh downhole environments was designed, manufactured, and tested in the laboratory and tested at the field to a up to 69 MPa and 250°C. This technology has high-temperature tolerance and has potential in downhole areas outside oil and gas, such as carbon capture and storage (CCS) and geothermal wells. The sensor concept has been proven in this project, but to create a commercially viable product, manufacturing a sensor with a smaller diameter needs to be performed.

02 PETROLEUM↗