Heat-sterilizable, remotely activated battery development program, phase 2 Quarterly report, 1 Apr. - 30 Jun. 1969
Design, components, and performance tests on heat sterilizable remotely activated battery
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Aerothermal modeling program, phase 1
The combustor performance submodels for complex flows are evaluated. The benchmark test cases for complex nonswirling flows are identified and analyzed. The introduction of swirl into the flow creates much faster mixing, caused by radial pressure gradients and increase in turbulence generation. These phenomena are more difficult to predict than the effects due to geometrical streamline curvatures, like the curved duct, and sudden expansion. Flow fields with swirl, both confined and unconfined are studied. The role of the dilution zone to achieve the turbine inlet radial profile plays an important part, therefore temperature field measurements were made in several idealized dilution zone configurations.
Srinivasan, R.↗
Project: Advanced Oxy-Combustion Technology Development and Scale Up for New and Existing Coal-Fired Power Plants (Phase II) (Final Report)
The objective of this project was to develop an advanced Oxy-Combustion Pressurized Fluidized Bed Combustor (Oxy-PFBC) technology and mature it to TRL 6 through pilot testing. Performance goals included demonstrating capture of 90% or greater of the produced carbon dioxide, with no more than a 35% increase in the cost of electricity. A 1 MWth pilot scale plant was designed, built and operated at CanmetENERGY in Ottawa. Extensive support work was carried out on component testing, analysis and commercial planning. The team members included GTI, Linde, Natural Resources Canada (CanmetENERGY), Pennsylvania State University, Electric Power Research Institute (EPRI), and General Electric. Additional research was provided by the University of Ottawa. Funding was provided by the US Department of Energy, Alberta Innovates and each of the team members. The total funding for Phase II was $\$$18.537M with $\$$12.058M. The period of performance for Phase II was from July 1, 2014 through December 31, 2018. Component testing conducted in preparation for pilot testing included cold flow testing at atmospheric and pressurized conditions, and coal and limestone reactivity tests at elevated temperatures and pressures. These tests validated in-bed heat exchanger heat transfer capability, bed stability, and coal particle residence time predictions. They also quantified coal and limestone reactivity at the expected combustor temperatures and pressures. The 1 MWth pilot testing achieved all performance goals with the exception of carbon conversion. The combustor achieved oxy-combustion at the full target pressure of 8 bar. Two key combustor performance goals that were achieved include exceeding the target sulfur capture in the combustor as well as exceeding the acid dewpoint target at full operating pressure. This validates assumptions about the pressures that can be achieved without acid gas condensation and the associated corrosion risks. The ability to achieve target operating pressures supports combustor cost assumptions. In addition, the CO 2 processing unit (CPU), demonstrated a new technology, the deoxidation (DeOxo) reactor. The CPU achieved all of its performance targets, while the DeOxo reactor demonstrated the ability to achieve 100 ppm or less of oxygen in the flue gas stream to meet CO 2 pipeline specs. The pilot combustor was damaged during testing and an incident investigation was conducted. The primary cause of the hardware damage was due to anomalous temperature readings, caused by sensors buried and insulated in bed particles trapped by heat exchanger tubes near the wall. This led to higher gas velocities than intended, which then caused lower fuel residence time, lower carbon conversion, freeboard burning, and undetected excess temperatures in the combustor. As a result, the TRL 6 goal was not achieved. Updated technoeconomic analysis predicts that the Oxy-PFBC can achieve the goal of <35% increase in COE with 90% CO 2 capture if the carbon conversion performance target can be demonstrated in future testing.
20 FOSSIL-FUELED POWER PLANTS↗
NASA's Space Launch System Gains Momentum Toward Integration and Testing
NASA’s Space Launch System (SLS) (Fig. 1) entered a new phase in 2017, completing major structural manufacturing on the core stage and delivering for launch the first flight hardware of the world’s most capable launch vehicle. The program is now in a stage of hardware assembly, integration and testing in preparation for the first integrated flight of SLS and the Orion crew vehicle. SLS is critical to U.S. leadership in future human and robotic space exploration, including a presence on the Moon in preparation for missions deeper into space. This paper will elaborate on SLS accomplishments in 2017 and plans for progress in 2018.
Askins, Bruce R.↗
Gen 3 Particle Pilot Plant (G3P3) -- High-Temperature Particle System for Concentrating Solar Power (Phases 1 and 2)
The U.S. Department of Energy Solar Energy Technologies Office initiated the Generation 3 Concentrating Solar Power (CSP) program to achieve higher operating temperatures (>700 °C) to enable next-generation CSP high-temperature power cycles such as the supercritical CO 2 (sCO2) Brayton Cycle. Three teams were selected to pursue high-temperature gas, liquid, and solid pathways for the heat-transfer media. Phases 1 and 2, which lasted from 2018 – 2020, consisted of design, modeling, and testing activities to further de-risk each of the technologies and develop a design for construction, commissioning, and operation of a pilot-scale facility in Phase 3 (2021 – 2024). This report summarizes the activities in Phases 1 and 2 for the solid-particle pathway led by Sandia National Laboratories. In Phases 1 and 2, Sandia successfully de-risked key elements of the proposed Gen 3 Particle Pilot Plant (G3P3) by improving the design, operation, and performance of key particle component technologies including the receiver, storage bins, particle-to-sCO2 heat exchanger, particle lift, and data acquisition and controls. Modeling and testing of critical components have led to optimized designs that meet desired performance metrics. Detailed drawings, piping and instrumentation diagrams, and process flow diagrams were generated for the integrated system, and structural analyses of the assembled tower structure were performed to demonstrate compliance with relevant codes and standards. Instrumentation and control systems of key subsystems were also demonstrated. Together with Bridgers & Paxton, Bohannan Huston, and Sandia Facilities, we have completed a 100% G3P3 tower design package with stamped engineering drawings suitable for construction bid in Phase 3.
14 SOLAR ENERGY↗
Three-Man Solid Electrolyte Carbon Dioxide Electrolysis Breadboard
The development of the Three-Man (2.2 lb CO2/man-day) Solid Electrolyte CO2 Electrolysis Breadboard consisted of a Phase 1 and 2 effort. The Phase 1 effort constituted fabrication of three electrolysis cell types and performing parametric testing, off-design testing, and cell life testing. The Phase 2 consisted of the preliminary design, incorporation of palladium (Pd) tubes for hydrogen separation from the electrolyzer cathode feed gases, design support testing, final design, fabrication, and performance testing of the breadboard system. The results of performance tests demonstrated that CO2 electrolysis in an oxygen reclamation system for long duration space-based habitats is feasible. Closure of the oxygen system loop, therefore, can be achieved by CO2 electrolysis. In a two step process the metabolic CO2 and H2O vapor are electrolyzed into O2, H2, and CO. The CO can subsequently be disproportionated into carbon and CO2 in a carbon deposition reactor and the CO2 in turn be recycled and electrolyzed for total O2 recovery. The development effort demonstrated electrolyzer system can be designed and built to operate safely and reliably and the incorporation of Pd tubes for hydrogen diffusion can be integrated safely with predictable performance.
Isenberg, Arnold O.↗
Interfacing the Generalized Fluid System Simulation Program with the SINDA/G Thermal Program
A general purpose, one dimensional fluid flow code has been interfaced with the thermal analysis program SINDA/G. The flow code, GFSSP, is capable of analyzing steady state and transient flow in a complex network. The flow code is capable of modeling several physical phenomena including compressibility effects, phase changes, body forces (such as gravity and centrifugal) and mixture thermodynamics for multiple species. The addition of GFSSP to SINDA/G provides a significant improvement in convective heat transfer modeling for SINDA/G. The interface development was conducted in two phases. This paper describes the first (which allows for steady and quasi-steady - unsteady solid, steady fluid - conjugate heat transfer modeling). The second (full transient conjugate heat transfer modeling) phase of the interface development will be addressed in a later paper. Phase 1 development has been benchmarked to an analytical solution with excellent agreement. Additional test cases for each development phase demonstrate desired features of the interface. The results of the benchmark case, three additional test cases and a practical application are presented herein.
Schallhorn, Paul↗
Initial Investigation into the Psychoacoustic Properties of Small Unmanned Aerial System Noise
For the past several years, researchers at NASA Langley have been engaged in a series of projects to study the degree to which existing facilities and capabilities, originally created for work on full-scale aircraft, are extensible to smaller scales --those of the small unmanned aerial systems (sUAS, also UAVs and, colloquially, `drones') that have been showing up in the nation's airspace of late. This paper follows an e ort that has led to an initial human{subject psychoacoustic test regarding the annoyance generated by sUAS noise. This e ort spans three phases: 1. The collection of the sounds through field recordings. 2. The formulation and execution of a psychoacoustic test using those recordings. 3. The initial analysis of the data from that test. The data suggests a lack of parity between the noise of the recorded sUAS and that of a set of road vehicles that were also recorded and included in the test, as measured by a set of contemporary noise metrics. Future work, including the possibility of further human subject testing, is discussed in light of this suggestion.
Christian, Andrew↗
Fabrication and Testing of Active and Adaptive Cyanate Ester Composite Mirrors
The objective of the NASA/Bennett Optical Research Inc. (BOR) NAS8-02008 Phase II Program, which also incorporated ideas developed under the earlier NASA NAS8-01035 Phase 1 Program, was to develop a large mirror fabrication and test facility with emphasis on producing large, light weight active and adaptive optics. A principle objective was to develop mandrels on which to make large composite graphite-filled cyanate ester mirrors, Deliverables were two of these superpolished lightweight active/adaptive optic composite mirrors, one 12" (approx.1/3 meter) in diameter and one 22" (approx.1/2 meter) in diameter. In addition optical superpolishers for mandrels up to 1.2 meters in diameter, test instruments for determining optical figure and scattered light, novel design actuators for making the composite mirrors both active and adaptive, and passive and active means for measuring actuator performance were developed at BOR. We are now installing a superpolisher capable of producing 3 meter diameter mirror/mandrels. All polishers utilize the principle of centrifugal elutriation and produce superpolished mandrels with surface microroughnesses under 1 nm rms.
Bennett, H. E.↗
Beryllium fastener technology
Program was conducted to develop, produce, and test optimum-configuration, beryllium prestressed and blind fasteners. The program was carried out in four phases - phase 1, feasibility study, phase 2, development, phase 3, evaluation of beryllium alloys, and phase 4, fabrication and testing.
Glackin, J. J.↗
Design and performance analysis of the DSS-13 beam waveguide antenna
A new 34 m research and development antenna is currently being constructed prior to introducing beam waveguide (BWG) antennas and Ka-band (32 GHz) frequencies into the NASA/JPL Deep Space Network. The new 34 m antenna, fed with either a center or bypass BWG, will lose less than 0.2 dB (excluding surface root mean square and mirror misalignment losses), as compared with a standard-fed Cassegrain antenna a X- (8.4 GHz) and Ka-bands. The antenna is currently under construction and is scheduled to be completed July 1990. Phase 1 of the project is for independent X- and Ka-band receive-only tests. Phase 2 of the project is for simultaneous S- (2.3 GHz) and X-band or X- and Ka-band operation, and the design is currently under way.
Veruttipong, T.↗
Integration and Testing Challenges of Small, Multiple Satellite Missions: Experiences from the Space Technology 5 Project
The ST5 payload, part of NASA s New Millennium Program headquartered at JPL, consisted of three micro satellites (approx. 30 kg each) deployed into orbit from the Pegasus XL launch. ST5 was a technology demonstration mission, intended to test new technologies for potential use for future missions. In order to meet the launch date schedule of ST 5, a different approach was required rather than the standard I&T approach used for single, room-sized satellites. The I&T phase was planned for spacecraft #1 to undergo integration and test first, followed by spacecraft #2 and #3 in tandem. A team of engineers and technicians planned and executed the integration of all three spacecraft emphasizing versatility and commonality. They increased their knowledge and efficiency through spacecraft #1 integration and testing and utilized their experience and knowledge to safely execute I&T for spacecraft #2 and #3. Each integration team member could perform many different roles and functions and thus better support activities on any of the three spacecraft. The I&T campaign was completed with STS s successful launch on March 22,2006
Sauerwein, Timothy A.↗
Laser Powder Bed Fusion Manufactured Alloys 625 and 282 and Properties Relevant to Advanced Nuclear Components
Under the Advanced Materials and Manufacturing Technologies program, two Ni-based alloys fabricated by laser powder bed fusion (LPBF) have been evaluated: γ′-strengthened Haynes 282 and solution-strengthened Inconel 625. Large printing defects were observed in the LPBF 282 alloy fabricated using a Renishaw AM250 machine, likely due to particle spattering during printing. Annealing at 1,180°C for 1 h followed by 4 h at 800°C in a high density of 50 nm γ′-strengthening precipitates as well as partial recrystallization resulted in a bimodal grain distribution. Creep testing performed at 750°C revealed lower creep life and ductility for the LPBF 282 compared with wrought 282. X-ray computed tomography combined with optical and scanning electron microscopy microstructural characterization revealed crack formation during creep testing, initiated either from printing defects or from creep cavitation at grain boundaries. Printing defects were the likely reason for the lower creep performance of LPBF 282 and could be suppressed by optimizing the build configuration. Printing 625 on an EOS M290 machine using the recommended EOS parameters resulted in a very low defect density. Superior creep strength at 725°C was observed for the as-printed LPBF 625 along the build direction when compared with wrought 625. No defect larger than ~50 µm could be detected by X-ray computed tomography in the as-printed conditions and after creep testing for 1,000 h at 725°C and 150 MPa. Small, needle-like δ-phase precipitates were observed after creep testing for 100 h at 725°C and 200 MPa. The rapid formation of the γ phase is directly related to the initial Nb and Mo segregation in the LPBF 625 cell walls, and its effect on the alloy’s high-temperature performance will be evaluated. Solution annealing was carried out at 1,150°C for 1 h and led to full recrystallization of the alloy. A decrease in strength and increase in ductility were observed after solution annealing, and the alloy recrystallization resulted in isotropic tensile properties at room temperature, contrary to what was observed for the as-printed LPBF 625.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Lacie phase 1 Classification and Mensuration Subsystem (CAMS) rework experiment
An experiment was designed to test the ability of the Classification and Mensuration Subsystem rework operations to improve wheat proportion estimates for segments that had been processed previously. Sites selected for the experiment included three in Kansas and three in Texas, with the remaining five distributed in Montana and North and South Dakota. The acquisition dates were selected to be representative of imagery available in actual operations. No more than one acquisition per biophase were used, and biophases were determined by actual crop calendars. All sites were worked by each of four Analyst-Interpreter/Data Processing Analyst Teams who reviewed the initial processing of each segment and accepted or reworked it for an estimate of the proportion of small grains in the segment. Classification results, acquisitions and classification errors and performance results between CAMS regular and ITS rework are tabulated.
Chhikara, R. S.↗
Propulsion and airframe aerodynamic interactions of supersonic V/STOL configurations, phase 1
A wind tunnel model of a supersonic V/STOL fighter configuration has been tested to measure the aerodynamic interaction effects which can result from geometrically close-coupled propulsion system/airframe components. The approach was to configure the model to present two different test techniques. One was a coventional test technique composed of two test modes. In the Flow-Through mode, absolute configuration aerodynamics are measured, including inlet/airframe interactions. In the Jet-Effects mode, incremental nozzle/airframe interactions are measured. The other test technique is a propulsion simulator approach, where a subscale, externally powered engine is mounted in the model. This allows proper measurement of inlet/airframe and nozzle/airframe interactions simultaneously.
Mraz, M. R.↗
DOME Reactor Testing User Guide
DOME User Guide History DOME User Guide Introduction User Engagement Lifecycle for DOME Phase 1 – Front End Engineering and Experiment Design (FEEED) Phase 2 – Detailed Design & Long Lead Procurement Phase 3 – Fabrication, Training, & Delivery Phase 4 – Installation & Testing Phase 5 – Removal & Disposal Next steps
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Experimental clean combustor program, phase 2
The primary objectives of this three-phase program are to develop technology for the design of advanced combustors with significantly lower pollutant emission levels than those of current combustors, and to demonstrate these pollutant emission reductions in CF6-50C engine tests. The purpose of the Phase 2 Program was to further develop the two most promising concepts identified in the Phase 1 Program, the double annular combustor and the radial/axial staged combustor, and to design a combustor and breadboard fuel splitter control for CF6-50 engine demonstration testing in the Phase 3 Program. Noise measurement and alternate fuels addendums to the basic program were conducted to obtain additional experimental data. Twenty-one full annular and fifty-two sector combustor configurations were evaluated. Both combustor types demonstrated the capability for significantly reducing pollutant emission levels. The most promising results were obtained with the double annular combustor. Rig test results corrected to CF-50C engine conditions produced EPA emission parameters for CO, HC, and NOX of 3.4, 0.4, and 4.5 respectively. These levels represent CO, HC, and NOX reductions of 69, 90, and 42 percent respectively from current combustor emission levels. The combustor also met smoke emission level requirements and development engine performance and installation requirements.
Gleason, C. C.↗
DOE Hanford Tank Side Cesium Removal System (TSCR) Update: Fabrication and Factory Acceptance Testing - 20300
The Tank Side Cesium Removal (TSCR) System is a modular, quickly-deployable, and passively safe system for efficiently removing solids and cesium from alkaline liquid waste raffinate created by fuel processing on the Hanford site. This paper provides an overview of the project with particular emphasis on completion of fabrication and factory acceptance testing (FAT). All TSCR System components are inside three enclosures known as the Process Enclosure, Ancillary Enclosure, and Control Enclosure. The Process Enclosure is seismic design category II (SDC-II) and built to withstand the rigors of transportation and lifting, high winds, volcanic ash fall, and heavy precipitation (snow) over a temperature range of -25 to 115 deg. F. The Process Enclosure and Control Enclosure were fabricated in AVANTech's Columbia, SC facility, while the Ancillary Enclosure was fabricated in AVANTech's Richland, WA facility. The design and preliminary documented safety analysis were completed in December 2019, with all work being performed in accordance with ASME NQA-1 quality assurance requirements. The Process Enclosure, Ion Exchange Columns (IXCs), and several other TSCR components have a nuclear safety function and are designated as safety significant structures, systems, and components (SS-SSCs). The NQA-1 Commercial Grade Dedication (CGD) process was used to identify critical characteristics in order to accept materials and items used for fabrication of several safety significant TSCR components. This paper also addresses unique aspects and challenges of implementing CGD in DOE facilities and systems. After fabrication and preliminary testing, the Process and Control Enclosures were shipped to AVANTech's Richland facility where the complete TSCR System was setup and connected in a represented layout and configuration that will be used on the Hanford site. Test tanks and pumps were put in place and connected to the TSCR Process Enclosure in a manner that mimicked interfacing Double Shell Tanks in the 241-AP Tank Farm. The TSCR System was then tested/operated under conditions equivalent to those planned for onsite operation. Testing was separated into five separate phases as defined below: - Phase 1: Confirmation of TSCR System readiness for the FAT; - Phase 2: Verification of TSCR System operation under standard conditions; - Phase 3: Demonstration of TSCR System operation under non-standard conditions; - Phase 4: Demonstration of ion exchange media removal from an IXC; and - Phase 5: Completion of TSCR System lift plans and site mobilization. The Hanford Tank Operations Contractor, Washington River Protection Solutions (WRPS), participated in all phases of testing. Testing at AVANTech's Richland Facility allowed WRPS personnel to familiarize themselves with TSCR operations in a radiologically clean facility prior to onsite mobilization. Engineering and operations personnel gained valuable experience that allowed them to better refine onsite operational protocols and procedures - including handling and movement of IXCs with a forklift. This paper describes the technologies used by the TSCR System as well as how these technologies are deployed and operated to advance the Hanford mission of safely, efficiently, and effectively treating tank waste. It also provides detailed information on fabrication and FAT, including operational data from simulated tank waste runs. A project schedule for WRPS' planned construction acceptance testing, operational acceptance testing, and actual tank waste treatment is provided. This presentation should be of great interest to parties responsible for the design, testing, and mobilization of modular NQA-1 technologies for the treatment of raffinate and similar liquid wastes containing high concentrations of radioactive cesium. (authors)
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗