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Development of a Macro-Batch Qualification Strategy for the Hanford Tank Waste Treatment and Immobilization Plant
The Savannah River National Laboratory (SRNL) has evaluated the existing waste feed qualification strategy for the Hanford Tank Waste Treatment and Immobilization Plant (WTP) based on experience from the Savannah River Site (SRS) Defense Waste Processing Facility (DWPF) waste qualification program. The current waste qualification programs for each of the sites are discussed in the report to provide a baseline for comparison. Recommendations on strategies are then provided that could be implemented at Hanford based on the successful Macrobatch qualification strategy utilized at SRS to reduce the risk of processing upsets or the production of a staged waste campaign that does not meet the processing requirements of the WTP. Considerations included the baseline WTP process, as well as options involving Direct High Level Waste (HLW) and Low Activity Waste (LAW) processing, and the potential use of a Tank Waste Characterization and Staging Facility (TWCSF). The main objectives of the Hanford waste feed qualification program are to demonstrate compliance with the Waste Acceptance Criteria (WAC), determine waste processability, and demonstrate unit operations at a laboratory scale. Risks to acceptability and successful implementation of this program, as compared to the DWPF Macro-Batch qualification strategy, include: Limitations of mixing/blending capability of the Hanford Tank Farm; The complexity of unit operations (i.e., multiple chemical and mechanical separations processes) involved in the WTP pretreatment qualification process; The need to account for effects of blending of LAW and HLW streams, as well as a recycle stream, within the PT unit operations; and The reliance on only a single set of unit operations demonstrations with the radioactive qualification sample. This later limitation is further complicated because of the 180-day completion requirement for all of the necessary waste feed qualification steps. The primary recommendations/changes include the following: Collection and characterization of samples for relevant process analytes from the tanks to be blended during the staging process; Initiation of qualification activities earlier in the staging process to optimize the campaign composition through evaluation from both a processing and glass composition perspective; Definition of the parameters that are important for processing in the WTP facilities (unit operations) across the anticipated range of wastes and as they relate to qualification-scale equipment; Performance of limited testing with simulants ahead of the waste feed qualification sample demonstration as needed to determine the available processing window for that campaign; and Demonstration of sufficient mixing in the staging tank to show that the waste qualification sample chemical and physical properties are representative of the transfers to be made to WTP. Potential flowcharts for derivatives of the Hanford waste feed qualification process are also provided in this report. While these recommendations are an extension of the existing WTP waste qualification program, they are more in line with the processes currently performed for SRS. The implementation of these processes at SRS has been shown to offer flexibility for processing, having identified potential processing issues ahead of the qualification or facility processing, and having provided opportunity to optimize waste loading and throughput in the DWPF.
SRNL Phase 1 Assessment of the WTP Waste Qualification Program
The Hanford Tank Waste Treatment and Immobilization Plant (WTP) Project is currently transitioning its emphasis from an engineering design and construction phase toward facility completion, start-up and commissioning. With this transition, the WTP Project has initiated more detailed assessments of the requirements that must be met during the actual processing of the Hanford Site tank waste. One particular area of interest is the waste qualification program. In general, the waste qualification program involves testing and analysis to demonstrate compliance with waste acceptance criteria, determine waste processability, and demonstrate laboratory-scale unit operations to support WTP operations. The testing and analysis are driven by data quality objectives (DQO) requirements necessary for meeting waste acceptance criteria for transfer of high-level wastes from the tank farms to the WTP, and for ensuring waste processability including proper glass formulations during processing within the WTP complex. Given the successful implementation of similar waste qualification efforts at the Savannah River Site (SRS) which were based on critical technical support and guidance from the Savannah River National Laboratory (SRNL), WTP requested subject matter experts (SMEs) from SRNL to support a technology exchange with respect to waste qualification programs in which a critical review of the WTP program could be initiated and lessons learned could be shared. The technology exchange was held on July 18-20, 2011 in Richland, Washington, and was the initial step in a multi-phased approach to support development and implementation of a successful waste qualification program at the WTP. The 3-day workshop was hosted by WTP with representatives from the Tank Operations Contractor (TOC) and SRNL in attendance as well as representatives from the US DOE Office of River Protection (ORP) and the Defense Nuclear Facility Safety Board (DNFSB) Site Representative office. The purpose of the workshop was to share lessons learned and provide a technology exchange to support development of a technically defensible waste qualification program. The objective of this report is to provide a review, from SRNL's perspective, of the WTP waste qualification program as presented during the workshop. In addition to SRNL's perspective on the general approach to the waste qualification program, more detailed insight into the specific unit operations presented by WTP during the workshop is provided. This report also provides a general overview of the SRS qualification program which serves as a basis for a comparison between the two programs. Recommendations regarding specific steps are made based on the review and SRNL's lessons learned from qualification of SRS low-activity waste (LAW) and high-level waste (HLW) to support maturation of the waste qualification program leading to WTP implementation.
Elimination of the Characterization of DWPF Pour Stream Sample and the Glass Fabrication and Testing of the DWPF Sludge Batch Qualification Sample
A recommendation to eliminate all characterization of pour stream glass samples and the glass fabrication and Product Consistency Test (PCT) of the sludge batch qualification sample was made by a Six-Sigma team chartered to eliminate non-value-added activities for the Defense Waste Processing Facility (DWPF) sludge batch qualification program and is documented in the report SS-PIP-2006-00030. That recommendation was supported through a technical data review by the Savannah River National Laboratory (SRNL) and is documented in the memorandums SRNL-PSE-2007-00079 and SRNL-PSE-2007-00080. At the time of writing those memorandums, the DWPF was processing sludge-only waste but, has since transitioned to a coupled operation (sludge and salt). The SRNL was recently tasked to perform a similar data review relevant to coupled operations and re-evaluate the previous recommendations. This report evaluates the validity of eliminating the characterization of pour stream glass samples and the glass fabrication and Product Consistency Test (PCT) of the sludge batch qualification samples based on sludge-only and coupled operations. The pour stream sample has confirmed the DWPF's ability to produce an acceptable waste form from Slurry Mix Evaporator (SME) blending and product composition/durability predictions for the previous sixteen years but, ultimately the pour stream analysis has added minimal value to the DWPF's waste qualification strategy. Similarly, the information gained from the glass fabrication and PCT of the sludge batch qualification sample was determined to add minimal value to the waste qualification strategy since that sample is routinely not representative of the waste composition ultimately processed at the DWPF due to blending and salt processing considerations. Moreover, the qualification process has repeatedly confirmed minimal differences in glass behavior from actual radioactive waste to glasses fabricated from simulants or batch chemicals. In contrast, the variability study has significantly added value to the DWPF's qualification strategy. The variability study has evolved to become the primary aspect of the DWPF's compliance strategy as it has been shown to be versatile and capable of adapting to the DWPF's various and diverse waste streams and blending strategies. The variability study, which aims to ensure durability requirements and the PCT and chemical composition correlations are valid for the compositional region to be processed at the DWPF, must continue to be performed. Due to the importance of the variability study and its place in the DWPF's qualification strategy, it will also be discussed in this report. An analysis of historical data and Production Records indicated that the recommendation of the Six Sigma team to eliminate all characterization of pour stream glass samples and the glass fabrication and PCT performed with the qualification glass does not compromise the DWPF's current compliance plan. Furthermore, the DWPF should continue to produce an acceptable waste form following the remaining elements of the Glass Product Control Program; regardless of a sludge-only or coupled operations strategy. If the DWPF does decide to eliminate the characterization of pour stream samples, pour stream samples should continue to be collected for archival reasons, which would allow testing to be performed should any issues arise or new repository test methods be developed.
Role of Accelerated Burnup Irradiation Testing in Support of Accelerated Fuel Qualification
Accelerated fuel qualification has gained attention as a means to reduce the time needed to realize new nuclear fuel concepts and expand the operating windows of existing fuel forms. A key component of this approach is accelerated burnup irradiation testing. Although the concept of accelerated burnup has been familiar to the community for many decades, the specifics about how the increasing fission rate may be used as a qualification tool have not yet been elucidated. The present work provides a vision of how accelerated fission rate testing can enable accelerated fuel qualification. Technology readiness levels (TRLs) are reintroduced to demarcate the stages of traditional fuel qualification, and accelerated fuel qualification is presented in this context. The critical steps needed to achieve each TRL are reframed within the context of modern nuclear materials research and development, as revolutionary fuel concepts are more common than previous eras. The practical impacts of accelerated fuel qualification approaches as applied to contemporary fuel qualification efforts are illustrated. Examples are given to illustrate how accelerated burnup irradiations are being used currently and could be applied in the future to support qualification and licensure. Finally, outstanding challenges in the application of accelerated burnup methods to nuclear fuel qualification are summarized, with priority placed on understanding how fission rate impacts diffusion, microstructure evolution, and other critical mechanisms that dictate fuel performance.
SRNL Phase 1 Assessment of the WAC/DQO and Unit Operations for the WTP Waste Qualification Program
The Hanford Tank Waste Treatment and Immobilization Plant (WTP) is currently transitioning its emphasis from a design and construction phase toward start-up and commissioning. With this transition, the WTP Project has initiated more detailed assessments of the requirements related to actual processing of the Hanford Site tank waste. One particular area of interest is the waste qualification program to be implemented to support the WTP. Given the successful implementation of similar waste qualification efforts at the Savannah River Site (SRS), based on critical technical support and guidance from the Savannah River National Laboratory (SRNL), WTP requested the utilization of subject matter experts from SRNL to support a technology exchange to perform a review of the WTP waste qualification program, discuss the general qualification approach at SRS, and to identify critical lessons learned through the support of DWPF's sludge batch qualification efforts. As part of Phase 1, SRNL subject matter experts in critical technical and/or process areas reviewed specific WTP waste qualification information. The Phase 1 review was a collaborative, interactive, and iterative process between the two organizations. WTP provided specific analytical procedures, descriptions of equipment, and general documentation as baseline review material. SRNL subject matter experts reviewed the information and, as appropriate, requested follow-up information or clarification to specific areas of interest. This process resulted in multiple teleconferences with key technical contacts from both organizations resolving technical issues that lead to the results presented in this report. This report provides the results of SRNL's Phase 1 review of the WAC-DQO waste acceptance criteria and processability parameters, and the specific unit operations which are required to support WTP waste qualification efforts. The review resulted in SRNL providing concurrence, alternative methods, or gap identification for the proposed WTP analytical methods or approaches. For the unit operations, the SRNL subject matter experts reviewed WTP concepts compared to what is used at SRS and provided thoughts on the outlined tasks with respect to waste qualification. Also documented in this report are recommendations and an outline on what would be required for the next phase to further mature the WTP waste qualification program.
AGR-3/4 Final Data Qualification Report for ATR Cycles 151A through 155B-1
This report provides the qualification status of experimental data for the entire Advanced Gas Reactor 3/4 (AGR 3/4) fuel irradiation. AGR-3/4 is the third in a series of planned irradiation experiments conducted in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) for the AGR Fuel Development and Qualification Program, which supports development of the advanced reactor technology under the INL ART Technology Development Office (TDO). The main objective of AGR-3/4 irradiation is to provide a known source of fission products for subsequent transport through compact matrix and structural graphite materials due to the presence of designed-to-fail fuel particles. Full power irradiation of the AGR 3/4 test began on December 14, 2011 (ATR Cycle 151A), and was completed on April 12, 2014 (end of ATR Cycle 155B) after 369.1 effective full power days of irradiation. The AGR-3/4 test was in the reactor core for eight of the ten ATR cycles between 151A and 155B. During the unplanned outage cycle, 153A, the experiment was removed from the ATR northeast flux trap (NEFT) location and stored in the ATR canal. This was to prevent overheating of fuel compacts due to higher than normal ATR power during the subsequent Powered Axial Locator Mechanism cycle, 153B. The AGR 3/4 test was inserted back into the ATR NEFT location during the outage of ATR Cycle 154A on April 26, 2013. Therefore, the AGR-3/4 irradiation data received during these 2 cycles (153A and 153B) are irrelevant and their qualification status isnot included in this report. Additionally, during ATR Cycle 152A the ATR core ran at low power for a short enough duration that the irradiation data are not used for physics and thermal calculations. However, the qualification status of irradiation data for this cycle is still covered in this report. As a result, this report includes data from 8 ATR Cycles: 151A, 151B, 152A, 152B, 154A, 154B, 155A, and 155B, as recorded in the Nuclear Data Management and Analysis System (NDMAS). The AGR 3/4 data streams addressed in this report include thermocouple (TC) temperatures, sweep gas data (flow rates, pressure, and moisture content), and Fission Product Monitoring System (FPMS) data (release rates, release to birth rate ratios [R/Bs], and particle failure counts) for each of the twelve capsules in the AGR 3/4 experiment. During Outage Cycle 155A, fourteen flow meters were installed downstream from fourteen FPMS monitors to measure flows from the monitors; qualification status of these data are also included in the report. The final data qualification status for these data streams is determined by a Data Review Committee (DRC) composed of AGR technical leads, Sitewide Quality Assurance (QA), and NDMAS analysts. For ATR Cycles 151A through 154B, the DRC convened on February 12, 2014, reviewed the data acquisition process, and considered whether the data met the requirements for data collection as specified in QA approved INL ART TDO data collection plans. The DRC also examined the results of NDMAS data testing and statistical analyses, and confirmed the qualification status of the data as given in this report. The qualification status of AGR-3/4 irradiation data during the first six cycles were previously reported in INL/EXT-14-31186 document. This report presents data qualification status for the entire AGR-3/4 irradiation.
Code Qualification of Structural Materials for AFCI Advanced Recycling Reactors
This report summarizes the further findings from the assessments of current status and future needs in code qualification and licensing of reference structural materials and new advanced alloys for advanced recycling reactors (ARRs) in support of Advanced Fuel Cycle Initiative (AFCI). The work is a combined effort between Argonne National Laboratory (ANL) and Oak Ridge National Laboratory (ORNL) with ANL as the technical lead, as part of Advanced Structural Materials Program for AFCI Reactor Campaign. The report is the second deliverable in FY08 (M505011401) under the work package 'Advanced Materials Code Qualification'. The overall objective of the Advanced Materials Code Qualification project is to evaluate key requirements for the ASME Code qualification and the Nuclear Regulatory Commission (NRC) approval of structural materials in support of the design and licensing of the ARR. Advanced materials are a critical element in the development of sodium reactor technologies. Enhanced materials performance not only improves safety margins and provides design flexibility, but also is essential for the economics of future advanced sodium reactors. Code qualification and licensing of advanced materials are prominent needs for developing and implementing advanced sodium reactor technologies. Nuclear structural component design in the U.S. must comply with the ASME Boiler and Pressure Vessel Code Section III (Rules for Construction of Nuclear Facility Components) and the NRC grants the operational license. As the ARR will operate at higher temperatures than the current light water reactors (LWRs), the design of elevated-temperature components must comply with ASME Subsection NH (Class 1 Components in Elevated Temperature Service). However, the NRC has not approved the use of Subsection NH for reactor components, and this puts additional burdens on materials qualification of the ARR. In the past licensing review for the Clinch River Breeder Reactor Project (CRBRP) and the Power Reactor Innovative Small Module (PRISM), the NRC/Advisory Committee on Reactor Safeguards (ACRS) raised numerous safety-related issues regarding elevated-temperature structural integrity criteria. Most of these issues remained unresolved today. These critical licensing reviews provide a basis for the evaluation of underlying technical issues for future advanced sodium-cooled reactors. Major materials performance issues and high temperature design methodology issues pertinent to the ARR are addressed in the report. The report is organized as follows: the ARR reference design concepts proposed by the Argonne National Laboratory and four industrial consortia were reviewed first, followed by a summary of the major code qualification and licensing issues for the ARR structural materials. The available database is presented for the ASME Code-qualified structural alloys (e.g. 304, 316 stainless steels, 2.25Cr-1Mo, and mod.9Cr-1Mo), including physical properties, tensile properties, impact properties and fracture toughness, creep, fatigue, creep-fatigue interaction, microstructural stability during long-term thermal aging, material degradation in sodium environments and effects of neutron irradiation for both base metals and weld metals. An assessment of modified versions of Type 316 SS, i.e. Type 316LN and its Japanese version, 316FR, was conducted to provide a perspective for codification of 316LN or 316FR in Subsection NH. Current status and data availability of four new advanced alloys, i.e. NF616, NF616+TMT, NF709, and HT-UPS, are also addressed to identify the R&D needs for their code qualification for ARR applications. For both conventional and new alloys, issues related to high temperature design methodology are described to address the needs for improvements for the ARR design and licensing. Assessments have shown that there are significant data gaps for the full qualification and licensing of the ARR structural materials. Development and evaluation of structural materials require a variety of experimental facilities that have been seriously degraded in the past. The availability and additional needs for the key experimental facilities are summarized at the end of the report. Detailed information covered in each Chapter is given.
NASA Progress on the Development and Qualification of a 12-kW Hall-Effect, Solar Electric Propulsion Thruster
I. Motivation and Background Beginning in 2014, the National Aeronautics and Space Administration (NASA) Space Technology Mission Directorate (STMD) began a project to increase the state of the art for the Hall-Effect Solar Electric Propulsion (SEP) technology. The resulting Advanced Electric Propulsion System (AEPS) project has developed a 12 kW Hall Current Thruster in support of the NASA mission to establish a permanent human presence in lunar orbit and to land the next American astronauts on the South Pole of the Moon. The project is led by the NASA Glenn Research Center, supported by the Jet Propulsion Laboratory and development, qualification & flight hardware all provided by L3 Harris Aerojet Rocketdyne (AR).The AEPS project has completed the development testing of a high power, solar electric propulsion Hall Current thruster that will be used on the NASA Power & Propulsion Element (PPE) of the Gateway space station. NASA initially built three Technology Development Units to understand key characteristics of the hall-effect rocket with magnetic shielding. The design led to development testing on two Engineering Test Unit Thrusters and multiple critical components. The project has begun production of the three flight thrusters and entered qualification testing at the component and thruster levels. II. Approach NASA and AR teams completed all development phases of the project, including full development and integration testing of the Engineering Model hardware, Critical Design Review, and ground test equipment validation, as well as fabrication and acceptance testing of the initial qualification thruster. Qualification and verification of the environmental and life requirements of the AEPS design was initiated in the Fall of 2023 and will be accomplished on two thruster units and using a series of component-level tests during 2024 and 2025. Environmental testing will incorporate functional reference firings, shock, vibration, and Thermal Vacuum (TVAC) testing. Life verification will assess the thruster wear and performance over the lifetime of the Gateway spacecraft. Critical component qualification tests include cathode heater, magnet coils, magnet heaters, temperature sensors, and a cathode assembly that will undergo life cycle testing on multiple units. Flight thrusters will complete assembly and acceptance testing and be delivered to the PPE program in early 2025. III. Preliminary and Anticipated Results The program has completed the acceptance testing, including dynamic testing and hot fire characterization, of the first qualification thruster. In the Fall of 2023, the program entered the environmental qualification phase for thruster testing. This paper will present an overview of the AEPS thruster project, thruster capabilities and flight design, preliminary results from the thruster acceptance and qualification testing, component life cycle testing and flight hardware status.
Hanford Tank Waste Treatment and Immobilization Plant (WTP) Waste Feed Qualification Program Development Approach - 13114
The Hanford Tank Waste Treatment and Immobilization Plant (WTP) is a nuclear waste treatment facility being designed and constructed for the U.S. Department of Energy by Bechtel National, Inc. and subcontractor URS Corporation (under contract DE-AC27-01RV14136 [1]) to process and vitrify radioactive waste that is currently stored in underground tanks at the Hanford Site. A wide range of planning is in progress to prepare for safe start-up, commissioning, and operation. The waste feed qualification program is being developed to protect the WTP design, safety basis, and technical basis by assuring acceptance requirements can be met before the transfer of waste. The WTP Project has partnered with Savannah River National Laboratory to develop the waste feed qualification program. The results of waste feed qualification activities will be implemented using a batch processing methodology, and will establish an acceptable range of operator controllable parameters needed to treat the staged waste. Waste feed qualification program development is being implemented in three separate phases. Phase 1 required identification of analytical methods and gaps. This activity has been completed, and provides the foundation for a technically defensible approach for waste feed qualification. Phase 2 of the program development is in progress. The activities in this phase include the closure of analytical methodology gaps identified during Phase 1, design and fabrication of laboratory-scale test apparatus, and determination of the waste feed qualification sample volume. Phase 3 will demonstrate waste feed qualification testing in support of Cold Commissioning. (authors)
EVOLUTION OF SPACE REACTOR QUALIFICATION METHODS AND A PATH FORWARD FOR NEW SPACE REACTORS UNDER CONSIDERATION
These slides outline the evolution of space reactor system qualifications and provide a potential framework for qualification of current space reactor concepts. Qualification approaches for SNAP 10A, SP-100, TOPAZ II, and Prometheus reactor systems will be discussed. Several qualification approaches from past reactors will be reviewed including: a component qualification approach demonstrated in the SNAP reactor program, a system level approach in the SP-100 program, adding additional features to an existing design in the TOPAZ program, and a combination of a computational and basic testing approach for the Prometheus reactor. Past and present test facilities will also be discussed and the impact of test facility availability (or existence) is discussed. A suggested approach that complies with the updated Presidential Directive (NSPM-20, August 2019) that is derived from previous program approaches will be discussed for qualification of future space reactors.
SLUDGE BATCH 7B QUALIFICATION ACTIVITIES WITH SRS TANK FARM SLUDGE
Waste Solidification Engineering (WSE) has requested that characterization and a radioactive demonstration of the next batch of sludge slurry - Sludge Batch 7b (SB7b) - be completed in the Shielded Cells Facility of the Savannah River National Laboratory (SRNL) via a Technical Task Request (TTR). This characterization and demonstration, or sludge batch qualification process, is required prior to transfer of the sludge from Tank 51 to the Defense Waste Processing Facility (DWPF) feed tank (Tank 40). The current WSE practice is to prepare sludge batches in Tank 51 by transferring sludge from other tanks. Discharges of nuclear materials from H Canyon are often added to Tank 51 during sludge batch preparation. The sludge is washed and transferred to Tank 40, the current DWPF feed tank. Prior to transfer of Tank 51 to Tank 40, SRNL typically simulates the Tank Farm and DWPF processes with a Tank 51 sample (referred to as the qualification sample). With the tight schedule constraints for SB7b and the potential need for caustic addition to allow for an acceptable glass processing window, the qualification for SB7b was approached differently than past batches. For SB7b, SRNL prepared a Tank 51 and a Tank 40 sample for qualification. SRNL did not receive the qualification sample from Tank 51 nor did it simulate all of the Tank Farm washing and decanting operations. Instead, SRNL prepared a Tank 51 SB7b sample from samples of Tank 7 and Tank 51, along with a wash solution to adjust the supernatant composition to the final SB7b Tank 51 Tank Farm projections. SRNL then prepared a sample to represent SB7b in Tank 40 by combining portions of the SRNL-prepared Tank 51 SB7b sample and a Tank 40 Sludge Batch 7a (SB7a) sample. The blended sample was 71% Tank 40 (SB7a) and 29% Tank 7/Tank 51 on an insoluble solids basis. This sample is referred to as the SB7b Qualification Sample. The blend represented the highest projected Tank 40 heel (as of May 25, 2011), and thus, the highest projected noble metals content for SB7b. Characterization was performed on the Tank 51 SB7b samples and SRNL performed DWPF simulations using the Tank 40 SB7b material. This report documents: (1) The preparation and characterization of the Tank 51 SB7b and Tank 40 SB7b samples. (2) The performance of a DWPF Chemical Process Cell (CPC) simulation using the SB7b Tank 40 sample. The simulation included a Sludge Receipt and Adjustment Tank (SRAT) cycle, where acid was added to the sludge to destroy nitrite and reduce mercury, and a Slurry Mix Evaporator (SME) cycle, where glass frit was added to the sludge in preparation for vitrification. The SME cycle also included replication of five canister decontamination additions and concentrations. Processing parameters were based on work with a nonradioactive simulant. (3) Vitrification of a portion of the SME product and characterization and durability testing (as measured by the Product Consistency Test (PCT)) of the resulting glass. (4) Rheology measurements of the SRAT receipt, SRAT product, and SME product. This program was controlled by a Task Technical and Quality Assurance Plan (TTQAP), and analyses were guided by an Analytical Study Plan. This work is Technical Baseline Research and Development (R&D) for the DWPF. It should be noted that much of the data in this document has been published in interoffice memoranda. The intent of this technical report is bring all of the SB7b related data together in a single permanent record and to discuss the overall aspects of SB7b processing.
WTP Waste Feed Qualification: Glass Fabrication Unit Operation Testing Report
The waste feed qualification program is being developed to protect the Hanford Tank Waste Treatment and Immobilization Plant (WTP) design, safety basis, and technical basis by assuring waste acceptance requirements are met for each staged waste feed campaign prior to transfer from the Tank Operations Contractor to the feed receipt vessels inside the Pretreatment Facility. The Waste Feed Qualification Program Plan describes the three components of waste feed qualification: 1. Demonstrate compliance with the waste acceptance criteria 2. Determine waste processability 3. Test unit operations at laboratory scale. The glass fabrication unit operation is the final step in the process demonstration portion of the waste feed qualification process. This unit operation generally consists of combining each of the waste feed streams (high-level waste (HLW) and low-activity waste (LAW)) with Glass Forming Chemicals (GFCs), fabricating glass coupons, performing chemical composition analysis before and after glass fabrication, measuring hydrogen generation rate either before or after glass former addition, measuring rheological properties before and after glass former addition, and visual observation of the resulting glass coupons. Critical aspects of this unit operation are mixing and sampling of the waste and melter feeds to ensure representative samples are obtained as well as ensuring the fabrication process for the glass coupon is adequate. Testing was performed using a range of simulants (LAW and HLW simulants), and these simulants were mixed with high and low bounding amounts of GFCs to evaluate the mixing, sampling, and glass preparation steps in shielded cells using laboratory techniques. The tests were performed with off-the-shelf equipment at the Savannah River National Laboratory (SRNL) that is similar to equipment used in the SRNL work during qualification of waste feed for the Defense Waste Processing Facility (DWPF) and other waste treatment facilities at the Savannah River Site. It is not expected that the exact equipment used during this testing will be used during the waste feed qualification testing for WTP, but functionally similar equipment will be used such that the techniques demonstrated would be applicable. For example, the mixing apparatus could use any suitable mixer capable of being remoted and achieving similar mixing speeds to those tested.
A method of hardware qualification for flight by analyses, similarity and integrated testing
The results are described of a study on four pieces of flight hardware from the Saturn 1U and S-4B stages to determine whether the objectives of the formal qualification tests on that hardware could have been obtained within that program by methods other than performing the qualification tests. These methods include qualification by analyses, similarity and integrated testing, i.e., distribution of the objectives among the other tests in the program. It was found that it is feasible to delete the requirements for formal qualification testing provided that it is accomplished early in the program to allow adequate planning for accomplishing the qualification objectives by other means. Additionally, a scorekeeping system was defined that is simple, straightforward, easy to implement. This scorekeeping system provides complete visibility of equivalent qualification status at any point during the program. A set of groundrules for implementing this study was established as a result of findings on the specific items of hardware studied.
BSM Delta Qualification 2, volume 3, book 2
This report, presented in three volumes, provides the results of a two-motor Delta Qualification 2 program conducted in 1993 to certify the following enhancements for incorporation into booster separation motor (BSM0 flight hardware: vulcanized-in-place nozzle aft closure insulation; new iso-static ATJ bulk graphite throat insert material, adhesive EA9394 for bonding the nozzle throat, igniter grain rod/centering insert/igniter case; deletion of the igniter adapter insulator ring; deletion of the igniter adapter/igniter case interface RTV; and deletion of loctite from igniter retainer plate threads. The enhancements above directly resulted from (1) the BSM total quality management (TQM) team initiatives to enhance the BSM producibility, and (2) the necessity to qualify new throat insert and adhesive systems to replace existing materials that will not be available. Testing was completed at both the component and motor levels. Component testing was accomplished to screen candidate materials (e.g., throat materials, adhesive systems) and to optimize processes (e.g., aft closure insulator vulcanization approach) prior to their incorporation into the test motors. Motor testing--consisting of two motors, randomly selected by USBI's on-site quality personnel from production lot AAY, which were modified to accept the enhancements -- was completed to provide the final qualification of the enhancements for incorporation into flight hardware. Volume 3, Book 2 provides various supporting documentation to the previous volumes with regards to the testing of the two Delta qualification units: data acceptance records, thermal conditioning analysis, igniter adapter thermal flake analysis, laboratory adhesive (EA-9394) qualification report, throat insert thermal/structural analysis, Delta Qualification Nonconformance Reports (NCR's), O-ring seating tests, and interim test report for vulcanization process qualification.
Research Needs for Developing Qualification Standards for Flight Simulation Training Devices with Head Mounted Displays
This presentation discusses research needs to support evidence-based qualification standards for Flight Simulation Training Devices (FSTDs) with head mounted displays (HMDs). Currently, the FAA and EASA have no qualification standards specifically for FSTDs using HMDs and extended reality (XR) visuals, and existing qualification standards may not be sufficient. Special Conditions can be prescribed for the evaluation and qualification of individual devices, but these Special Conditions need to be assessed and adjusted on a case-by-case basis resulting in an elaborate process. Furthermore, test tolerances used in Special Conditions are often based on conventional visual systems and may not be adequate. This presentation first identifies gaps in the current knowledge of using HMDs in pilot training, and, more specifically, using HMDs in the training of manual aircraft control with motion cues. Next, research is proposed to help close these gaps, inform the development of qualification criteria and tolerances, and guide efforts to update regulations. The Vertical Motion Simulator (VMS) at NASA Ames Research Center, with its large motion capability, is currently undergoing significant upgrades including a state-of-the-art out-the-window visual system. In addition, an HMD capability will be introduced to use in conjunction with the conventional visual system. With its long history of setting standards in the simulation industry, the VMS is the ultimate tool to conduct research that could help accelerate the development of standards for the use of HMDs in FSTDs. The goal of the talk is ultimately to spark a discussion about the research needs and priorities to best serve the development of new qualification standards.
Qualification Testing of Engineering Camera and Platinum Resistance Thermometer (PRT) Sensors for Mars Science Laboratory (MSL) Project under Extreme Temperatures to Assess Reliability and to Enhance Mission Assurance
Package Qualification and Verification (PQV) of advanced electronic packaging and interconnect technologies and various other types of qualification hardware for the Mars Exploration Rover/Mars Science Laboratory flight projects has been performed to enhance the mission assurance. The qualification of hardware (Engineering Camera and Platinum Resistance Thermometer, PRT) under extreme cold temperatures has been performed with reference to various project requirements. The flight-like packages, sensors, and subassemblies have been selected for the study to survive three times (3x) the total number of expected temperature cycles resulting from all environmental and operational exposures occurring over the life of the flight hardware including all relevant manufacturing, ground operations and mission phases. Qualification has been performed by subjecting above flight-like qual hardware to the environmental temperature extremes and assessing any structural failures or degradation in electrical performance due to either overstress or thermal cycle fatigue. Experiments of flight like hardware qualification test results have been described in this paper.
A review of neutronics and thermal hydraulics–based screening methods applied to accelerated nuclear fuel qualification
This paper reviews the state-of-the-art engineering approach for using thermal hydraulic (TH) and neutronics modeling and simulation (M&S) tools to perform rapid screening studies of novel nuclear fuel concepts within the context of accelerated fuel qualification. Global research efforts have introduced nuclear fuel and material concepts that mark a significant departure from traditional reactor materials. The number of new technologies being considered for development for light water reactors and advanced reactor types has created the need for an accelerated fuel qualification procedure. A key component of this procedure is the rapid identification of the most promising fuel concepts using computational screening studies. Advanced TH and neutronic M&S tools should be leveraged to efficiently determine whether the reactor performance and safety characteristics of a given concept warrant additional studies or whether the concept requires modification or elimination. This paper reviews best practices for performing these TH and neutronics screening studies at various stages during a fuel concept's progression through the qualification procedure. The motivation behind standardizing this approach is to minimize time and resources spent on qualification activities for fuel concepts that could be quickly refined or eliminated from consideration based on their reactor physics and TH characteristics. Adoption of this screening procedure—which focuses primarily on nuclear fuels but may be applicable to other reactor materials—will also help accelerate new material qualification by generating boundary conditions crucial to fuel performance evaluations and highlighting needed areas of separate effects experimentation. This article reviews the motivation behind the introduction of novel nuclear fuel concepts, provides incentive for utilizing TH- and neutronics-based screening studies, describes the screening approach and methodology, and includes discussion on how to interpret screening results to provide recommendations for the continued development of a given concept.