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DOE OSTI2019

Double-Shell Tank Primary Bottom Inspection Development - 19067

Double-Shell Tank (DST) integrity at Hanford is maintained with a variety of activities such as ultrasonic and visual inspections, chemistry controls, corrosion monitoring and structural analyses methods [1]. A pressing need for the Double-Shell Tank Integrity Program is the ability to inspect the bottom of the tanks. Though the DSTs' annulus spaces (the space between the internal and external tank walls) have been inspected visually since 1992 and with Ultrasonic Testing (UT) since 1996, WRPS has been unable to conduct inspections of the tank bottoms due to limitations of available technology, omitting about 40 percent of the tank surface below the maximum fill level from routine inspection. Visual inspections of the tank annulus have been conducted up to five times in some DSTs and the annulus space for all of the DSTs has been inspected twice with UT. The annulus region includes the walls of the primary tank and secondary liner along with accessible portions of the secondary liner bottom. Due to the lack of under-tank inspection technology, degradation of the primary tank bottom in Tank AY-102 was undetected until the tank leaked into its annulus space, confirmed in 2012 [2]. Since that time, WRPS has been working with the nondestructive examination community and the Pacific Northwest National Laboratory to evaluate potential technologies to conduct these challenging remote inspections. Recent work has included the development, testing, and deployment of several remote visual inspection technologies to observe the condition of the primary tank bottom of the DSTs by leveraging air distribution slots in the refractory pad on which it rests. Robotic solutions to conduct this inspection were developed with a detailed understanding of the physical configuration and operational logistics. Understanding and subsequent communication of these details to vendors within the robotics and nondestructive examination community was a critical component to the successful production of these new tools. In total, two remote visual inspection tools were produced by two vendors. The first tool was designed to leverage existing ultrasonic testing magnetic wall crawler technology in use within the double-shell tank annuli at Hanford. This resulted in a cost savings, immediate familiarization with the equipment, and a more streamlined shop to field experience. The second tool was developed from the ground up, and represents a more tailored and purpose-built solution to the problem. While costlier and more complex, it is also more versatile and capable of future growth or adaptation. Initial design of both tools began in early FY17 with fabrication and testing completed in early FY18. The tools were designed to be deployed alongside existing inspection operations and expand coverage. Development of visual inspection tools to evaluate the primary tank bottom region of the double-shell tanks was planned as the first stage of inspection. Continued development of volumetric sensors and incorporation of these inspection tools into Hanford's ongoing Double-Shell Tank Integrity Program are the next steps, continuously seeking to expand understanding of asset integrity and remaining useful life. (authors)

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DOE OSTI2018

Miniature Inspection Robot for Restricted Access exploration (MIRRAX) - 18324

The MIRRAX remote inspection vehicle has been developed to explore and characterise enclosed legacy facilities on the Sellafield site which have limited access ports. Its re-configurable design means that it can be deployed through a 150 mm port before changing its footprint shape to provide a stable platform for mobile characterisation. It can support both geometric and radiometric scanning. (authors)

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DOE OSTI2020

Double-Shell Tank Primary Bottom Visual Inspection Results - 20025

A pressing need for the Double-Shell Tank Integrity Program at Hanford is of the ability to inspect the bottom of the tanks. Though the DSTs' annulus spaces (the space between the internal and external tank walls) have been inspected visually since 1992 and with Ultrasonic Testing (UT) since 1996, inspections of the tank bottoms have been able to be conducted due to limitations of available technology, omitting about 40 percent of the tank surface below the maximum fill level from routine inspection. Visual inspections of the tank annulus have been conducted up to five times in some DSTs and portions of the annulus space for all of the DSTs has been inspected twice with UT. This region includes the walls of the primary tank and secondary liner along with accessible portions of the secondary liner bottom. Due to this lack of technology, the degradation of the primary tank bottom in Tank AY-102 was undetected until the tank leaked into its annulus space, confirmed in 2012. Since that time, WRPS has been working with the nondestructive examination community and the Pacific Northwest National Laboratory, to evaluate potential technologies to conduct these challenging remote inspections. Recent work has included the development, testing, and deployment of several remote visual inspection technologies to observe the condition of the primary tank bottom of the DSTs by leveraging air distribution slots in the refractory pad on which it rests. Robotic solutions to conduct this inspection were developed with a detailed understanding of the physical configuration and operational logistics. Understanding and subsequent communication of these details to vendors within the robotics and nondestructive examination community was a critical component to the successful production of these new tools. Throughout the FY16-FY18 years, vendors from nondestructive examination community were solicited for ideas to meet the tank bottom inspection challenge. Two tank bottom visual inspection solutions were then pursued to meet that challenge. Both tools were successfully deployed at Tank AP-107, and provided valuable visuals, never before obtained from the under tank environment of a double-shell tank. While there are minor opportunities for improvement identified with each system, general outcomes were overwhelmingly positive. Both systems were successfully able to navigate the refractory air slot pattern from the outer edge to the tank center and record video footage. The micro-crawler provided high quality and very stable footage through the air slot pattern, but took longer to deploy into the slots and traverse through them than the alternative system. The push-pull tethered camera was able to navigate all seven of its target air slots in a matter of a few hours, which included deployment, movement between slot entrances, and complete removal of the system from the annulus environment. Through these air slots, new information was gained about the tank bottom and refractory pad condition of tank AP-107, AP-106, AP-108, and AN-102. While some debris was noted in the air slots, including sand, chipped refractory, and construction materials, the refractory was found to be structurally stable and adequately supporting the primary tank bottom through the full diameter of the tank. Primary tank bottom steel exterior was found to be in good condition, free of ongoing or aggressive corrosion conditions. Looking toward the future, robotic access to and visual inspection of refractory air slots and the primary tank bottom steel has now proven viable. Incorporating periodic air slot inspections as a regular practice within the Double-Shell Tank Integrity Program is the next step, allowing trending of any changes in condition. As ultrasonic testing infrastructure was leveraged to complete the initial system deployments described in this report, it makes sense to adopt that same strategy for ongoing periodic examinations and deploy these primary tank bottom inspection tools alongside ultrasonic testing operations. Development of visual inspection tools to evaluate the primary tank bottom region of the double-shell tanks was planned as the first stage of inspection. Continued development of volumetric sensors and incorporation of these inspection tools into Hanford's ongoing Double-Shell Tank Integrity Program are the next steps, seeking to continuously expand understanding of asset integrity and remaining useful life. (authors)

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NASA NTRS1969

Remote disassembly and inspection of NRX-A6 reactor.

Remote disassembly and inspection methods for evaluating NRX-AG reactor components performance

Bouille, J. R.↗

DOE OSTI2019

R and DE Robotic Sensor Intern Team: Remote 3D Mapping Overview

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DOE OSTI2018

H-Canyon Ventilation System Exhaust Tunnel Inspection at the Savannah River Site - 18052

The Department of Energy (DOE) H-Canyon Facility at the Savannah River Site (SRS) is operated by Savannah River Nuclear Solutions (SRNS). The Facility Structural Integrity Program (SIP) performs periodic visual inspections to confirm the component is capable of performing its safety function. This Program provides the process to document the conditions of safety related structural systems and components, their damage mechanisms, and recommend repairs if required before there is impact on the safety envelope. The H-Canyon Exhaust Tunnel is part of the H-Canyon Exhaust Ventilation System and is periodically inspected under the Structural Integrity Program. The Tunnel performs a Safety Class passive design feature function that is available 100% of the time. The Tunnel directs Canyon process air from the Canyon to the Sand Filter System. The radiological and chemical airborne activity coupled with the physical configuration of the tunnel precludes a manned entry into the tunnel. Tunnel inspections have been performed using cameras on a stick, referred to as pole cameras prior to CY2003. Since CY2003, five camera equipped crawlers have been used with varying levels of inspection success. With each successive crawler inspection, expectations have increased to perform tasks beyond visual examinations. The 2017 crawler performed the visual inspection but also included improvements on crawler performance, such as testing the use of wireless capability and remediation of crawler travel route, to the addition of stationary cameras and lighting at key locations. The latest 2017 crawler successfully traveled the entire length of the tunnel between the Canyon and Sand Filter System for the second time since development, thus providing key visual data for the integrity program [2]. In addition, several access ports were installed in 2017 following the removal of concrete core samples that allow for new visual inspection of the Canyon Crossover tunnel, thus providing information for an area that was generally inaccessible for monitoring. Planning for the 2019 crawler inspection is underway with the expectations to improve upon inspection cameras and also introduce mapping technologies such as LIDAR. The challenge to obtain meaningful data from the remote inspections of a 60+ year operating Canyon Exhaust tunnel continues to be a complex endeavor requiring close coordination of multiple organizations, adherence to Conduct of Operations, Radiological Safety, Worker Safety, etc. principles as well as alignment with Facility Safety Basis requirements. This paper discusses the continuing improvements in inspection techniques and the challenges associated these inspections. (authors)

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NASA NTRS2016

Remote Strain Sensing of CFRP Using Microwave Frequency Domain Reflectometry

NASA's Advanced Composites Project is investigating technologies that increase automated remote inspection of aircraft composite structures. Therefore, microwave Frequency Domain Reflectometry (FDR) is being investigated as a method of enabling rapid remote measurement of strain occurring at the first ply of a composite fiber reinforced polymer (CFRP) structure using Radio Frequency (RF) Electro-Magnetic (EM) radiation. While microwave reflectometry has been used to detect disbonds in CFRP structures, its use in detecting strain has been limited. This work will present data demonstrating the measurement of the reactance changes due to loading conditions that are indicative of strain in a CFRP structure. In addition, the basic EM signature will be presented along with an analysis of temperature and humidity effects.

Wilson, William C.↗

DOE OSTI2019

Lidar Mapping and Surveillance of Nuclear Infrastructure

Wear is unavoidable, whether it occurs in a nuclear facility or abridge on the highway its detection is crucial to preventing the failure of a system. While tools capable of detecting localized damage exist, industry lacks methods to evaluate the health of larger infrastructure. Routine inspection of nuclear facilities must be undertaken to ensure the safety of personnel and proper containment of nuclear materials. Most systems in a nuclear facility are designated as radioactive and confined spaces. To constantly monitor such systems in person would be hazardous but with a remote inspection tool it can be done in a safer and easier way. Lidar: Operates by emitting a laser pulse and looking for the reflected light. Allows user to gain 3D information of the environment. Project Objective: To develop an inspection tool for evaluating the health of large scale infrastructure using Lidar and machine learning. Autonomous Platform + Lidar + Data Fusion + Big Data. Use SLAM to build a 2D map of the environment. Point cloud created by transforming the points between reference frames. Point cloud to Surface: Inherent representation of surface geometry; Difficult to process with conventional techniques. Point cloud to Image: Easily processed by conventional machine learning algorithms. The quantity of data generated will necessitate a big data framework to manage the data for processing. Additional Sensors: Detecting the temperature (a) chemical makeup (b) and radiation emission (c) of a surface could assist in detecting problems. Human inspection can detect irregularities in both physical objects and their point-cloud representations. This is a good indication that mapping nuclear sites using Lidar will provide qualitative insight into the health of the facility. If deep learning can be used to automatically identify problem areas then the completed tool could become an invaluable asset.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1994

Multiple-Segment Climbing Robots

Multiple-segment climbing robots developed to perform such tasks as inspection, sandblasting, welding, and painting on towers and other structures. Look and move like caterpillars. Video camera mounted on one of segments rotated to desired viewing angle. Used in remote inspection of structure, to view motion of robot and/or provides video feedback for control of motion, and/or to guide operation of head mounted on foremost segment with motorized actuators.

Kerley, James↗

DOE OSTI2019

R and DE Robotic Sensor Intern Team: Advanced Sensor Suite Prototype

The Department of Energy (DOE) nuclear complex includes many hazardous and challenging environments that must be inspected remotely and routinely for structural integrity evaluation and long-term planning purposes. The H-Canyon Air Exhaust (HCAEX) Tunnel is an example of such an environment where a biannual inspection is currently performed. Presently inspections are performed by teleoperated robotic crawlers which provide low-res video feedback to the structural engineers. Advanced sensors: including Lidar and panospheric hi-res cameras have the potential to provide additional valuable data in future inspections. The primary goal of the sensor suite is to provide an internal 3D map of the HCAEX tunnel. Possible sensors were a stereo camera, a 3D Lidar, or a 2D Lidar that would need to be spun around. The issues with the stereo camera were that it does not have a large field-of-view and that its depth information was not nearly as accurate as even the baseline Lidars. The Hokuyo UTM-30LX-EW shown below provides a 270 deg. FOV with high accuracy and resolution while the largest FOV on a 3D Lidar is 40 deg. This was the reason a 2D Lidar was chosen over the 3D Lidar. Even though the 2D Lidar requires additional components and software to generate a 3D map, its FOV advantage is too great given that the HCAEX tunnel is a relatively confined space. Along with the Lidar, a camera sensor, IMU sensor, pan-tit unit, and on board computer needed to be identified. The two panospheric cameras allow for full 360 deg. FOV. The IMU will give data on the state of the robot inside the tunnel. The computer is used to gather and process data on board and to control the pan-tilt system. Mounts were designed and 3D printed to build the prototype of the sensor suite. It was designed to have the Lidar on top With its full FOV free while having the camera below and as close to together as possible while still leaving much of their FOV visible. The design also managed the cables such that they were unlikely to be damaged if in tension and so that they did not intrude much on the cameras vision. The sensor tree developed for the H-Canyon tunnel inspection project produces a large quantity of camera and Lidar data. a postprocessing pipeline was created to facilitate the analysis of these data. The pipeline follows the following routine: 1) Registration - Salient local features in subsequent scans are identified and used to align the scans With one another. This allows production of a single cohesive map of the tunnel. 2) Sensor Fusion - RGB camera data is 'painted' onto the depth data created by the Lidar. 3) Segmentation - Individual surfaces from within the scene are segmented out separately for individual analysis. 4) Degradation Analysis - Automatic mapping of local deviation from the plane in position or surface normal is performed, as is detection of exposed rebar using Lidar return intensity. 2) Obstacle Detection - Lidar data is also used in real time to detect obstacles in the environment. This could give feedback to the operator to successfully drive in the tunnel. 6) Graphic User Interface - a custom GUI was created to facilitate customer use of the system. The system provides real-time feedback from both the cameras and Lidar. The Lidar point-cloud data is also used for obstacle detection. As the Lidar spins, various algorithms are run to analyze the current 'slice' and obstacles in the environment are determined and registered on a cost-map. A Graphical User Interface (GUI) was developed to allow the user to easily command the crawler to set the rotational speed of the Lidar, perform a scan, and register and save the 3D generated cloud after a scan is done. For the good of the crawler, a critical aspect of the GUI design is to allow the user to cancel a scan any time after it is commanded and before it is saved. The sensor trees depth accuracy was evaluated in comparison to a high end commercial FARO Terrestrial Laser Scanner (TLS) with specifications for millimeter accuracy at distances above 10 m. For the purposes of these tests, the depth measurements produced by the TLS were taken as ground truth. Example test wall panels were scanned with the TLS and postprocessed with its proprietary software, and subsequently scanned with the sensor tree system. The two scans were manually aligned and for each point in the output cloud from the sensor tree, the distance to the nearest ground truth point in the FARO cloud was determined. 98.7% of all produced points were within the specified target range of 6 mm, with an average deviation of 1.75 mm. The test walls used have an overall in-wall depth variation of around 40 mm.

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NASA NTRS2017

Electric Potential and Electric Field Imaging with Dynamic Applications & Extensions

The technology and methods for remote quantitative imaging of electrostatic potentials and electrostatic fields in and around objects and in free space is presented. Electric field imaging (EFI) technology may be applied to characterize intrinsic or existing electric potentials and electric fields, or an externally generated electrostatic field made be used for volumes to be inspected with EFI. The baseline sensor technology (e-Sensor) and its construction, optional electric field generation (quasi-static generator), and current e- Sensor enhancements (ephemeral e-Sensor) are discussed. Critical design elements of current linear and real-time two-dimensional (2D) measurement systems are highlighted, and the development of a three dimensional (3D) EFI system is presented. Demonstrations for structural, electronic, human, and memory applications are shown. Recent work demonstrates that phonons may be used to create and annihilate electric dipoles within structures. Phonon induced dipoles are ephemeral and their polarization, strength, and location may be quantitatively characterized by EFI providing a new subsurface Phonon-EFI imaging technology. Results from real-time imaging of combustion and ion flow, and their measurement complications, will be discussed. Extensions to environment, Space and subterranean applications will be presented, and initial results for quantitative characterizing material properties are shown. A wearable EFI system has been developed by using fundamental EFI concepts. These new EFI capabilities are demonstrated to characterize electric charge distribution creating a new field of study embracing areas of interest including electrostatic discharge (ESD) mitigation, manufacturing quality control, crime scene forensics, design and materials selection for advanced sensors, combustion science, on-orbit space potential, container inspection, remote characterization of electronic circuits and level of activation, dielectric morphology of structures, tether integrity, organic molecular memory, atmospheric science, weather prediction, earth quake prediction, and medical diagnostic and treatment efficacy applications such as cardiac polarization wave propagation and electromyography imaging.

Generazio, Ed↗

NASA NTRS2017

Electric Potential and Electric Field Imaging with Dynamic Applications: 2017 Research Award Innovation

The technology and methods for remote quantitative imaging of electrostatic potentials and electrostatic fields in and around objects and in free space is presented. Electric field imaging (EFI) technology may be applied to characterize intrinsic or existing electric potentials and electric fields, or an externally generated electrostatic field may be used for illuminating volumes to be inspected with EFI. The baseline sensor technology (e-Sensor) and its construction, optional electric field generation (quasi-static generator), and current e- Sensor enhancements (ephemeral e-Sensor) are discussed. Critical design elements of current linear and real-time two-dimensional (2D) measurement systems are highlighted, and the development of a three dimensional (3D) EFI system is presented. Demonstrations for structural, electronic, human, and memory applications are shown. Recent work demonstrates that phonons may be used to create and annihilate electric dipoles within structures. Phonon induced dipoles are ephemeral and their polarization, strength, and location may be quantitatively characterized by EFI providing a new subsurface Phonon-EFI imaging technology. Initial results from real-time imaging of combustion and ion flow, and their measurement complications, will be discussed. These new EFI capabilities are demonstrated to characterize electric charge distribution creating a new field of study embracing areas of interest including electrostatic discharge (ESD) mitigation, crime scene forensics, design and materials selection for advanced sensors, combustion science, on-orbit space potential, container inspection, remote characterization of electronic circuits and level of activation, dielectric morphology of structures, tether integrity, organic molecular memory, atmospheric science, and medical diagnostic and treatment efficacy applications such as cardiac polarization wave propagation and electromyography imaging.

Generazio, Ed↗

DOE OSTI2022

CEBAF Accelerator Tunnel Robot Project

Advancements in the field of robotics allow for the use of remotely controlled robots to perform tasks that have typically required human intervention. Jefferson Lab has explored the possibilities of robots placed in the accelerator tunnel to perform remote inspections that would otherwise require powering down equipment and completing lengthy radiological surveys that impact beam operations. A robotic solution ? driven by a human operator ? could not only reduce accelerator down time but also support the Lab's radiation exposure policy (known as "ALARA" - As Low As Reasonably Acceptable) by handling routine tunnel and beamline investigations in place of a human being. However, operating a remote device in a radioactive, high electronic-noise area is not a trivial task and drop-in solutions are rarely as simple as they seem. We will present the past prototypes that were tested as well follow-on technology developed from the project. We will also briefly survey current applications of robots at accelerator facilities with an eye toward future applications.

McGuckin, Theodore↗

NASA NTRS2020

Laser Based Remote and Rapid Inspection for Composite Plates

Composites have been extensively used in aero structure and become the predominate components in the new airframes. Thus, rapid and effective inspection for composite structures is highly desired in aerospace engineering in order to shorten the certificate cycle for new structures or provide safety guarantee for existing ones. In this paper, a laser based remote Lamb wave inspection system is presented and implemented on composite plates for simulated damage detection. The system employs pulsed laser (PL) and scanning laser Doppler vibrometer (SLDV) for noncontact and remote Lamb wave actuation and wavefield sensing. A composite plate with simulated defect (surface bonded quartz rod) is inspected with the PL-SLDV laser system. Wave scattering are observed in the SLDV acquired wavefield and the damage is further evaluated with wavefield imaging and frequency wavenumber analysis. Potential application towards automatic PL Lamb wave excitation is also explored through employing an industry robotic arm towards rapid inspection.

Lamb waves↗

DOE OSTI2018

GMLC Southeast Regional Consortium: Technology Driven Improvements to Power Grid Resiliency

Recognizing that electric grid challenges can differ by geographical regions across the US, the Department of Energy (DOE) created a pioneer regional partnership to provide technical assistance to stakeholders facing grid modernization challenges. The southeast regional teams will transfer technologies developed under DOE auspices to stakeholders for testing, evaluation, and market validation. Regional members will help define critical challenges and pave the way for transition of technologies to the commercial sector. Using the depth and expertise at Oak Ridge National Laboratory, Savannah River National Laboratory, University of Tennessee’s CURENT, CAPER and the Clemson 20 MVA Electrical Grid Laboratory—along with critical industry partners, such as Duke Energy, TVA, Southern Company, EPB, and Santee Cooper—the Southeast Regional Consortium team will conduct collaborative research to advance the state of the grid in the Southeast region and improve power system resiliency to enhance responsiveness, enable faster restoration of power, and increase distributed energy resource (DER) concentrations. This report provides details of the technical research and demonstration projects accomplished by Oak Ridge National Laboratory (ORNL) as part of the Southeast Regional Consortium. Specifically, ORNL analyzed the application of optical current and voltage measurements impedance relays which would enable step distance protection to be deployed on distribution systems. This would improve the precision of determining the geographic location of faults, increase network topology flexibility, and allow bi-directional power flow. Next, ORNL deployed time sensitive networking technology on the EPB fiberoptic data network to study the impact of increased sensor traffic on existing supervisory control and data acquisition data. The deterministic latency and high bandwidth were demonstrated by remotely inspecting a substation using a drone with full HD streaming video operated at the EPB Control Center. Finally, a new application-based communication and control system developed at ORNL call CSEISMIC was tested for future deployment on the EPB Control Center microgrid using a hardware-in-the-loop testbed that was also developed at ORNL. The controller was able to successfully optimize ancillary service when the microgrid is connected to the distribution network. The seamless islanding, resynchronization, and reconnection of the microgrid was also demonstrated through the testing.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1979

Ultrasonic grating checks electron-beam welds

Remote inspection technique uses reflectance of ultrasonic waves from machined steps in root area of electron beam welds to indicate sound or faulty welds.

Mitchell, H. A.↗

NASA NTRS1982

A microprocessor application in the MTV telemetry data processor

An engineering model of the Telemetry Data Processor monitoring and display system used by the Maneuverable Television (MTV) employed in remote inspections of the Space Shuttle has been developed, incorporating the MC 6809 microprocessor. The system acquires analog and digital signals from the MTV flyer and converts them into engineering units, formatting them in several pages according to their function. Upon request, a data page can be superimposed on the video signal from the MTV camera. In addition, the system monitors key parameters for out-of-limit conditions and flashes caution and warning messages on the selected page.

Spahn, C. J.↗

NASA NTRS1994

Simplified Generation Of Distance Images

Optoelectronic apparatus undergoing development intended to produce digitized images that contain three-dimensional information: brightness of each picture element in digitized image depends on distance from apparatus to corresponding location in scene. Does not contain mechanical scanners. Signal-processing circuitry in this apparatus simpler. Smaller, weighs less, and consumes less power. Potential applications include automated inspection, remote exploration, robotic manipulators, robotic vehicles, and maneuvering and docking systems.

Wesolowicz, Karl↗