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Bench testing of an early prototype pitch resonator WEC
This report describes a series of tests performed on a "pitch resonator'" concept for a wave energy converter. The overall testing campaign goals centered on risk reduction for the pitch resonator wave energy converter concept and model validation. Two modes of testing are captured in this report: one using a single degree of freedom test rig and one in which a six degree of freedom Stewart platform was employed.
Optical Test Bench (SYSM 5620 Final Report)
The National Ignition Facility (NIF) is a research facility that focuses on High Energy Density Science and Inertial Confinement Fusion. In the NIF, 192 laser beams are directed into a miniscule Target Capsule to generate an implosion – this is called a NIF Shot. Many NIF Users conduct experiments using different Targets and laser inputs to generate reactions that are of interest to the scientific community. Those reactions are monitored using various Target Diagnostic instruments, including Shot Time Photography – which provides crucial images of the Target as the implosion occurs. A subset of these NIF Users is less interested in the reaction itself and more interested in subjecting materials or devices to the intense environment that these reactions can create. Using the Target as a source of x-rays, neutrons, or blast loading for particular materials has been significant to the shock physics community and to those who work in extreme design spaces. However, the Material and Radiation Effects team – that performs these experiments on behalf of the NIF Users – has not been able to make good use of the existing Shot Time Photography Diagnostics. The STP cameras are focused on the Targets rather than the MRE Customers’ materials, the current system is not oriented to have a good view of the MRE Customers’ materials, and the cameras are limited in their capabilities (black and white, poor resolution, etc.). As MRE experiments increase in quantity and importance to the scientific community, the desire for visual monitoring of the experiments to substantiate models and inform other data is also rising.
Bench-test Investigation of the Transient-response Characteristics of Several Simulated Airplanes Incorporating an Autopilot Sensitive to Yawing Accelerations
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Characteristics of the BMW 801D2 Automatic Engine Control as Determined from Bench Tests
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Molecular Sieve Bench Testing and Computer Modeling
The design of an efficient four-bed molecular sieve (4BMS) CO2 removal system for the International Space Station depends on many mission parameters, such as duration, crew size, cost of power, volume, fluid interface properties, etc. A need for space vehicle CO2 removal system models capable of accurately performing extrapolated hardware predictions is inevitable due to the change of the parameters which influences the CO2 removal system capacity. The purpose is to investigate the mathematical techniques required for a model capable of accurate extrapolated performance predictions and to obtain test data required to estimate mass transfer coefficients and verify the computer model. Models have been developed to demonstrate that the finite difference technique can be successfully applied to sorbents and conditions used in spacecraft CO2 removal systems. The nonisothermal, axially dispersed, plug flow model with linear driving force for 5X sorbent and pore diffusion for silica gel are then applied to test data. A more complex model, a non-darcian model (two dimensional), has also been developed for simulation of the test data. This model takes into account the channeling effect on column breakthrough. Four FORTRAN computer programs are presented: a two-dimensional model of flow adsorption/desorption in a packed bed; a one-dimensional model of flow adsorption/desorption in a packed bed; a model of thermal vacuum desorption; and a model of a tri-sectional packed bed with two different sorbent materials. The programs are capable of simulating up to four gas constituents for each process, which can be increased with a few minor changes.
Test Bench Developments at the NASA Langley Liner Technology Facility
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Special report, cross calibration of JHU test equipment with GSFC vacuum optical bench
Tests were conducted to confirm the validity of the absolute calibrations which have been performed with the Apollo 17 ultraviolet spectrometer (UVS) in the calibration test equipment (CTE) which were constructed for that purpose. To accomplish this the prototype UV spectrometer SN/01 was retrofitted to be substantially identical to the qualification unit and to the two flight units. It was renamed the cross calibration unit (CCU). The instrument was first calibrated in the JHU calibration test equipment (CTE), then installed in the vacuum optical bench (VOB) at Goddard Space Flight Center and calibrated. The following day a second CTE calibration was conducted which provided substantially the same calibration values as were obtained on the first CTE calibration, and showed remarkably close agreement with the VOB calibration values at two of the wavelengths which were studied. The VOB results at the third wavelength (1216 A) indicate the CTE calibration at 1216 A is 15% too low. This apparent discrepancy is discussed and presents a very important result of the cross calibration effort.
Site bench maintenance test set
Bench-maintenance test set for spacecraft instrumentation system
A vacuum optical bench for testing space experiment packages.
Vacuum optical bench /VOB/ spacecraft testing facility for calibration of telescopes, radiometers, spectrographs and monochromators and measurement of intensity distribution, radiation source and contamination
Considerations for testing full-scale wind turbine nacelles with hardware-in-the-loop
In this paper, pole placement control techniques are utilized to compensate for variations in the torsional dynamics resulting from the different boundary conditions experienced by a wind turbine nacelle when mounted on a test bench. Simulation case studies are used to understand the baseline torsional characteristics of the nacelle coupled to the test bench versus that coupled to the rotor. It was found that the frequency shifts by up to 200% and 400% for the first and second torsional modes, respectively. The feasibility of utilizing pole placement technique to match the torsional characteristics of the turbine on the test bench is investigated using PI and PID controllers. Here, the performance of the tuned controller is then verified under two test scenarios: Low Voltage Ride Through (LVRT), and a highly dynamic turbulent wind input. It is demonstrated that tuning the test bench speed controller can effectively shift the poles of the closed-loop system to match the desired first and second modes of the full turbine and replicate transient field events on the test bench.
Advances in benchmarking and round robin testing for PEM water electrolysis: Reference protocol and hardware
While the number of publications in the PEM water electrolysis community increases each year, no common ground concerning reference hardware (test cells and test bench) and testing protocols has been yet established. This would, however, be necessary for the comparability of experimental results. First attempts for such reference hardware and procedures have been made in the framework of the Task 30 Electrolysis within the Technology Collaboration Programme on Advanced Fuel Cells (AFC TCP) of the International Energy Agency (IEA). Since then, improvements of both the test hardware (test cell and components) as well as the measurement protocol were identified, and a revised methodology and key results based on a comprehensive measurement series have been obtained. A detailed protocol for testing commercial reference components with a reference laboratory test cell developed in-house by Fraunhofer ISE is presented. For evaluation of the protocol and the hardware, it was tested at three different institutions at the same time. Impedance spectroscopic and polarization data was acquired and analyzed. The obtained differences in performance were calculated to give the community an expectation window to compare own data to. Finally, the importance of a thorough temperature control and the conditioning phase are demonstrated.
Development and Bench-Scale Testing of a Novel Biphasic Solvent-Enabled Absorption Process for Post-Combustion Carbon Capture (Final Technical Report)
A new class of biphasic solvents was developed, and the concept of the enabled carbon dioxide (CO 2 ) absorption process was tested for post-combustion carbon capture in our previous lab-scale research. The primary goals of this project were to advance the development of the novel biphasic CO 2 absorption process (BiCAP) and validate its technical advantages by testing the integrated technology at a 40 kWe bench-scale with actual coal-derived flue gas in a power plant environment. The project was led by the University of Illinois at Urban-Champaign (UIUC), and Trimeric Corporation served as a sub-awardee providing support in basic design and techno-economic studies. To achieve the project goals and objectives, solvent management studies, process modeling and optimization, bench-scale equipment design, construction and testing, and technical, economic and environmental assessments have been conducted. The two top-performing biphasic solvents developed in our previous research were used in this project. Biphasic solvent emissions and control were investigated in the laboratory. The emissions of the biphasic solvents from the absorber were comparable to or lower than the reference 30 wt% monoethanolamine (MEA) solution, while they could be more effectively removed in the water wash column. Lab-scale testing of solvent degradation reclamation has revealed that vacuum distillation was feasible for biphasic solvent reclamation. Aspen Plus models were used to optimize the BiCAP, and a CO 2 stripping configuration introducing a secondary cold solvent feed to the stripper was identified to be the most energy efficient. A 40 kWe bench-scale, integrated BiCAP system was successfully designed, fabricated, and installed at the UIUC’s Abbott Power Plant. Parametric testing with synthetic flue gas has demonstrated that the two biphasic solvents required a more than 40% lower heat duty for CO 2 desorption as compared to the reference MEA tested on the same bench-scale skid. Slipstream testing with actual coal flue gas for a total of 31 days in two test campaigns has further demonstrated stable operation of the bench-scale skid. During the first campaign targeting 90% CO 2 removal, the heat duty averaged at 2,183 MJ/tonne of CO 2 captured and during the second campaign targeting 95% removal, the heat duty averaged at 2,450 MJ/tonne of CO 2 captured. A techno-economic analysis has revealed that for integration of the BiCAP into a 650-MWe pulverized coal-fired power plant, the parasitic power loss was reduced by ~20%, and the cost of CO 2 capture was reduced by ~21% ($36.3/tonne on a December 2018 dollar basis) compared to the U.S. Department of Energy (DOE)’s baseline Case B12B. As progression from this bench-scale development effort, a new project “Engineering-Scale Testing of the Biphasic Solvent Based CO 2 Absorption Capture Technology at a Covanta Waste-to-Energy Facility” was awarded by the DOE, launched in February 2023, to allow the team to further test the technology and demonstrate its technical and economic advantages at a pilot scale.
Tri-Gas Pressurization System Testing and Modeling for Cryogenic Applications
The use of Tri‐gas in rocket propulsion systems is somewhat of a new technology. This paper defines Tri‐gas as a mixture of gases composed largely of helium with a small percentage of a stoichiometric mixture of hydrogen and oxygen. When exposed to a catalyst the hydrogen and oxygen in the mixture combusts, significantly raising the temperature of the mixture. The increase in enthalpy resulting from the combustion process significantly decreases the required quantity of gas needed to pressurize the ullage of the vehicle propellant tanks. The objective of this effort was to better understand the operating characteristics of Tri‐gas in a pressurization system with low temperature applications. In conjunction with ongoing programs at NASA Marshall Space Flight Center, an effort has been undertaken to evaluate the operating characteristics of Tri‐gas through modeling and bench testing. Through improved understanding of the operating characteristics, the risk of using this new technology in a launch vehicle propulsion system was reduced. Bench testing of Tri‐gas was a multistep process that targeted gas characteristics and performance aspects that pose a risk to application in a pressurization system. Pressurization systems are vital to propulsion system performance. Keeping a target ullage pressure in propulsions tanks is necessary to supply propellant at the conditions and flow rates required to maintain desired engine functionality. The first component of testing consisted of sampling Tri‐gas sources that had been stagnant for various lengths of time in order to determine the rate at which stratification takes place. Second, a bench test was set up in which Tri‐gas was sent through a catalyst bed. This test was designed to evaluate the performance characteristics of Tri‐gas, under low temperature inlet temperatures, in a flight‐like catalyst bed reactor. The third, most complex, test examined the performance characteristics of Tri‐gas at low temperature temperatures in a test configuration built to more closely resemble a vehicle pressurization system. The results of these bench tests address various risks that all relate to underperformance of Tri‐gas pressurization systems.
Bench-Scale Testing of Monolithic PPI Structured Contactors for Direct Air Capture of CO 2
The overall project objective was to develop, optimize and bench-scale test the integrated embodiment of a leading direct air capture (DAC) sorbent composition, linear-poly(propylenimine) (l-PPI), in a structured material system, specifically a monolithic contactor for achieving low pressure drop, to justify its further scale-up in a subsequent program. The project team was led by CORMETECH, a leading monolithic gas/solid contactor manufacturer for environmental applications, and included Global Thermostat, a well-known DAC start-up, and Georgia Tech, a prominent US academic institution in carbon capture and DAC. The monolithic contactor for l-PPI in this project employed an advanced, cost-effective fabrication technique from CORMETECH, namely a porous monolith substrate directly impregnated with the amine, an approach contrasting to the traditional wash-coating methods used for activating monoliths. The l-PPI monolithic contractor is targeted for use in DAC systems such as the Global Thermostat DAC process, which involves the cyclic operation of ambient air flow over a monolithic amine contactor followed by steam-mediated thermal desorption and CO 2 collection, maximizing volumetric productivity while reducing the auxiliary power required to capture CO 2 from air. The Global Thermostat DAC process currently utilizes poly(ethyleneimine) (PEI) materials as baseline sorbents, which are subject to oxidative degradation and slow capacity fade at the elevated temperature required for efficient CO 2 removal. Georgia Tech, with Global Thermostat, had discovered in lab-scale efforts that l-PPI had superior resistance to oxidative degradation compared to PEI, with similar CO 2 adsorption capacity. While the novel l-PPI sorbent offers significant advantages over PEI for DAC, including potential design simplification and increased process efficiency, it is not commercially available, and prior to this project, had not yet been evaluated on the bench-scale in a structured contactor.
Evaluation of dynamic testing of full-scale wind turbine drivetrains with hardware-in-the-loop
Dynamometer testing of full-scale wind turbine drivetrains involves subjecting integrated components to extreme static loads, fatigue loads, or dynamic loads to replicate field conditions. This paper provides a detailed evaluation of the uncertainty and errors in applied loads and measured responses, and their magnitude relative to established repeatability bounds for a drivetrain subjected to static and dynamic loads on the 7.5 MW test bench at the Clemson University Wind Turbine Drivetrain Testing Facility. An ideal drivetrain simulation model is utilized to isolate the influence of load tracking errors on test article responses. It is shown that the test article response variations are mainly driven by run out and clearances inherent to the drivetrain. For the dynamic profiles, the load tracking errors are within acceptable limits. Furthermore, a frequency analysis is used to show that the test bench controller tracking performance is acceptable for profiles with frequency content up to 1.5 Hz.
A Framework for Robust Multivariable Optimization of Integrated Circuits in Space Applications
Application Specific Integrated Circuit (ASIC) design for space applications involves multiple challenges of maximizing performance, minimizing power and ensuring reliable operation in extreme environments. This is a complex multidimensional optimization problem which must be solved early in the development cycle of a system due to the time required for testing and qualification severely limiting opportunities to modify and iterate. Manual design techniques which generally involve simulation at one or a small number of corners with a very limited set of simultaneously variable parameters in order to make the problem tractable are inefficient and not guaranteed to achieve the best possible results within the performance envelope defined by the process and environmental requirements. What is required is a means to automate design parameter variation, allow the designer to specify operational constraints and performance goals, and to analyze the results in a way which facilitates identifying the tradeoffs defining the performance envelope over the full set of process and environmental corner cases. The system developed by the Mixed Signal ASIC Group (MSAG) at the Goddard Space Flight Center is implemented as framework of software modules, templates and function libraries. It integrates CAD tools and a mathematical computing environment, and can be customized for new circuit designs with only a modest amount of effort as most common tasks are already encapsulated. Customization is required for simulation test benches to determine performance metrics and for cost function computation. Templates provide a starting point for both while toolbox functions minimize the code required. Once a test bench has been coded to optimize a particular circuit, it is also used to verify the final design. The combination of test bench and cost function can then serve as a template for similar circuits or be re-used to migrate the design to different processes by re-running it with the new process specific device models. The system has been used in the design of time to digital converters for laser ranging and time-of-flight mass spectrometry to optimize analog, mixed signal and digital circuits such as charge sensitive amplifiers, comparators, delay elements, radiation tolerant dual interlocked (DICE) flip-flops and two of three voter gates.
Bench-Scale Testing of a High Efficiency, Ultra-Compact Process for Pre-Combustion CO 2 Capture (Final Report)
The overarching objective of this bench-scale study is to field-validate the technical feasibility of a membrane- and adsorption-enhanced water gas shift (WGS) reaction process that employs a carbon molecular sieve (CMS) membrane reactor (MR) followed by an adsorption reactor (AR) for pre-combustion CO 2 capture while demonstrating progress towards achievement of the overall performance goals of CO 2 capture with 95% CO 2 purity at a cost of electricity (COE) of 30% less than the baseline capture approaches. The main goal of this bench-scale project is to advance the proposed MR-AR transformative CO 2 capture technology to a sufficient maturity level so that our present industrial partners (M&PT and Worley) can potentially adapt the technology for further small pilot-scale testing. The project began at TRL 4, as the system prototype had already been validated in the laboratory on simulated syngas (as part of project DE-FE0026423). The project ended at TRL 5, via scaling-up of the prototype system and testing it on actual syngas at a host site (CAER at the University of Kentucky (UKy)). The project was carried-out in two different phases: In Phase I (during BP1 of the project), the team designed, constructed, and assembled the bench-scale experimental MR-AR system, prepared the membranes, adsorbents, and catalysts, tested the bench-scale unit with simulated syngas to validate functionality, and prepared a preliminary TEA of the technology. In Phase II (during BP2 of the project), the team installed the unit at the test site at the UKy site and completed all utility connections and hookups, field-tested the novel MR-AR process in the bench-scale system using real syngas, collected and analyzed experimental data, and completed a detailed TEA of the technology. A key aim of the project was to identify and address the technical and process risks and to generate information to advance the technology to the next stage of development. All project milestones and success criteria were met. Specifically, the team: (i) designed, constructed and assembled a bench scale system that handled 1 – 5 scfm syngas and tested its functionality with simulated syngas; (ii) prepared high performance CMS membrane tubes (ID: 3.5 mm, OD: 5.7 mm, 30” long) that meet the target H 2 permeance ( > 1 m 3 /(m 2 .hr.bar) or (> 370.3 GPU)) and a target H 2 /CO selectivity >80 at the relevant temperature (up to 300oC) and pressure conditions (up to 25 bar) with a <10% decline in performance over each 250 hr. testing period (iii) procured commercial sour-shift catalyst in sufficient quantity and prepared up to 10 kg of pelletized adsorbent for use at relevant conditions (250oC 2.5wt.% and target sorbent attrition rate < 0.2; (iv) installed the bench-scale unit at the test site (UKy) and tested the MR-AR technology using real syngas for over 250 hr. for both static and flow experiments; (v) updated the TEA analysis based on bench-scale data and met CO 2 capture goals of 95% CO 2 purity at a cost of electricity 30% less than baseline capture approaches. The CMS membranes, HTC adsorbents and catalysts employed all exhibited very robust and stable performance during the long-term run (over a >250 hr live syngas run). Furthermore, the proposed MR-AR IGCC system achieved a LCOE with a N 2 sale price of $\$$ 30/ton, with N 2 compression (no N 2 compression) of 101.2 $\$$/MWh (95.3 $\$$/MWh), which represents a 29.8% (33.9%) LCOE reduction in the baseline IGCC with carbon capture of 144.2 $\$$/MWh. The proposed MR-AR IGCC delivers a CO 2 capture cost of 44.8 $\$$/tonne (39.9 $\$$/tonne) vs 98.1 $\$$/tonne of the baseline capture case and a net power production of 586 MWe (623 MWe) vs 556 MWe of the baseline capture case.