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At least 487 records · Page 27

The Strategic Value of Human Factors Engineering in Control Room Modernization

Control room modernization is one of the most challenging and complex upgrade projects that a nuclear power plant can undertake. It can have almost as big an impact on operations as, for example, turbine replacement. The challenges of migrating an analog control system to a distributed control system are already well known and a number of nuclear utilities have embarked upon various levels of effort to upgrade some of the systems in the control room. When planning for control room upgrades, plants have to deal with a multitude of engineering, operational, and regulatory impacts. This will inevitably include several human factors considerations, such as workstation ergonomics, viewing angles, lighting, seating, new interaction modalities, new communication requirements, and new concepts of operation. In helping nuclear power utilities to deal with these challenges, the United States Department of Energy researchers located at Idaho National Laboratory (INL) have developed research-based human factors design and evaluation methods to be used in the development of end-state concepts for modernized control rooms and to manage the various phases of the upgrade life cycle. The methodology includes interactive sessions with operators in INL’s Human System Simulation Laboratory, three-dimensional modeling to visualize control board changes and operator-system interaction, and development of human-system prototypes to evaluate various aspects of proposed modifications. This methodology has been applied at a number of U.S. nuclear power plants where modernization projects are underway, including Exelon’s Braidwood and Byron plants, and Arizona Public Service's Palo Verde plant. It was demonstrated that including this methodology in the plant’s engineering process helps to ensure an integrated and cohesive outcome that is consistent with human factors engineering principles and provide substantial improvement in operator performance.

99 GENERAL AND MISCELLANEOUS↗

Corrosion Resistance of Amorphous Fe 49.7 Cr 17.7 Mn 1.9 Mo 7.4 W 1.6 B 15.2 C 3.8 Si 2.4 Coating: A New Criticality Control Material

Here, an iron-based amorphous metal with good corrosion resistance and a high absorption cross section for thermal neutrons has been developed and is reported here. This amorphous alloy has the approximate formula Fe 49.7 Cr 17.7 Mn 1.9 Mo 7.4 W 1.6 B 15.2 C 3.8 Si 2.4 and is known as SAM2X5. Chromium, molybdenum, and tungsten were added to provide corrosion resistance, while boron was added to promote glass formation and the absorption of thermal neutrons. Since this amorphous metal has a higher boron content than conventional borated stainless steels, it provides the nuclear engineer with design advantages for criticality control structures with enhanced safety. While melt-spun ribbons with limited practical applications were initially produced, large quantities (several tons) of gas-atomized powder have now been produced on an industrial scale, and applied as thermal-spray coatings on prototypical half-scale spent-nuclear-fuel containers and neutron-absorbing baskets. These prototypes and other SAM2X5 samples have undergone a variety of corrosion testing, including both salt-fog and long-term immersion testing. Modes and rates of corrosion have been determined in various relevant environments and are reported here. While these coatings have less corrosion resistance than melt-spun ribbons and optimized coatings produced in the laboratory, substantial corrosion resistance has been achieved.

36 MATERIALS SCIENCE↗

Site-Selective Polar Compensation of Mott Electrons in a Double-Perovskite Heterointerface

Double-perovskite oxides (DPOs) with two transition metal ions ($A_{2}BB'O_{6}$) offer a fascinating platform for exploring exotic physics and practical applications. Studying these DPOs as ultrathin epitaxial films on single crystalline substrates can add another dimension to engineering electronic, magnetic, and topological phenomena. Understanding the consequence of polarity mismatch between the substrate and the DPO would be the first step toward this broad goal. Here, we investigate this by studying the interface between a prototypical insulating DPO $Nd_{2}NiMnO_{6}$ and a wide band gap insulator $SrTiO_{3}$. The interface is found to be insulating in nature. By combining several experimental techniques and density functional theory, we establish a site-selective charge compensation process that occurs explicitly at the Mn site of the film, leaving the Ni sites inert. We further demonstrate that such surprising selectivity, which cannot be explained by existing mechanisms of polarity compensation, is directly associated with their electronic correlation energy scales. This study establishes the crucial role of Mott physics in polar compensation process and paves the way for designer doping strategies in complex oxides.

density functional theory↗

Distant Observer™ [SWR-12-09]

Distant Observer™ (DO) is an optical measurement tool, designed for parabolic trough solar collectors, that determines reflector slope error, absorber position error, and the combined errors based on images of the receiver-tube reflection taken from different angles. We have demonstrated that DO can provide a measurement accuracy of 0.25 mrad for the slope and receiver position errors. DO has two implementation versions: ground-based and drone-driven. As we pursue efforts to lower the capital and installation costs of parabolic trough solar collectors, it is essential to maintain high optical performance. The Distant Observer™ (DO) tool, developed by engineers at NREL, is a fast and highly accurate tool that provides complete characterization of the performance of the optical components which include the mirror panels and thermal receiver. This tool is very useful for testing both prototype and operational modules. The Distant Observer™ is an optical measurement tool for parabolic solar collectors that measures reflector slope error, absorber position error and the combined errors. Reflector slope errors occur for many reasons including imperfection in structural frame design, manufacturing and assembly. Absorber position error can be caused by poor structural design, poor installation, sag from the absorber weight, or change in the structure over time.

Ihas, Benjamin↗

Coastal Ohio Wind Project

The Coastal Ohio Wind Project intends to address problems that impede deployment of wind turbines in the coastal and offshore regions of Northern Ohio. The project evaluates different wind turbine designs and the potential impact of offshore turbines on migratory and resident birds by developing multidisciplinary research, which involves wildlife biology, electrical and mechanical engineering, and geospatial science. Firstly, the project conducts cost and performance studies of two- and three-blade wind turbines using a turbine design suited for the Great Lakes. The numerical studies comprised an analysis and evaluation of the annual energy production of two- and three-blade wind turbines to determine the levelized cost of energy. This task also involved wind tunnel studies of model wind turbines to quantify the wake flow field of upwind and downwind wind turbine-tower arrangements. The experimental work included a study of a scaled model of an offshore wind turbine platform in a water tunnel. The levelized cost of energy work consisted of the development and application of a cost model to predict the cost of energy produced by a wind turbine system placed offshore. The analysis found that a floating two-blade wind turbine presents the most cost effective alternative for the Great Lakes. The load effects studies showed that the two-blade wind turbine model experiences less torque under all IEC Standard design load cases considered. Other load effects did not show this trend and depending on the design load cases, the two-bladed wind turbine showed higher or lower load effects. The experimental studies of the wake were conducted using smoke flow visualization and hot wire anemometry. Flow visualization studies showed that in the downwind turbine configuration the wake flow was insensitive to the presence of the blade and was very similar to that of the tower alone. On the other hand, in the upwind turbine configuration, increasing the rotor blade angle of attack reduced the wake size and enhanced the vortices in the flow downstream of the turbine-tower compared with the tower alone case. Mean and rms velocity distributions from hot wire anemometer data confirmed that in a downwind configuration, the wake of the tower dominates the flow, thus the flow fields of a tower alone and tower-turbine combinations are nearly the same. For the upwind configuration, the mean velocity shows a narrowing of the wake compared with the tower alone case. The downwind configuration wake persisted longer than that of an upwind configuration; however, it was not possible to quantify this difference because of the size limitation of the wind tunnel downstream of the test section. The water tunnel studies demonstrated that the scale model studies could be used to adequately produce accurate motions to model the motions of a wind turbine platform subject to large waves. It was found that the important factors that affect the platform is whether the platform is submerged or surface piercing. In the former, the loads on the platform will be relatively reduced whereas in the latter case, the structure pierces the wave free surface and gains stiffness and stability. The other important element that affects the movement of the platform is depth of the sea in which the wind turbine will be installed. Furthermore, the wildlife biology component evaluated migratory patterns by different monitoring systems consisting of marine radar, thermal IR camera and acoustic recorders. The types of radar used in the project are weather surveillance radar and marine radar. The weather surveillance radar (1988 Doppler), also known as Next Generation Radar (NEXRAD), provides a network of weather stations in the US. Data generated from this network were used to understand general migratory patterns, migratory stopover habitats, and other patterns caused by the effects of weather conditions. At a local scale our marine radar was used to complement the datasets from NEXRAD and to collect additional monitoring parameters such as passage rates, flight paths, flight directions, and flight altitudes of nocturnal migrating species. Our work focused on the design and development of custom built marine radar that used t-bar and parabolic dish antennas. The marine radar used in the project was Furuno (XANK250) which was coupled with a XIR3000B digitizing card from Russell Technologies for collection of the radar data. The radar data was processed by open source radR processing software using different computational techniques and methods. Additional data from thermal IR imaging cameras were collected to detect heat emitted from objects and provide information on movements of birds and bats, data which we used for different animal flight behavior analysis. Lastly, the data from the acoustic recorders were used to provide the number of bird calls for assessing patterns and peak passage rates during migration. The development of the geospatial database included collection of different data sources that are used to support offshore wind turbine development. Many different data sets were collected and organized using initial version of web-based repository software tools that can accommodate distribution of rectified pertinent data sets such as the lake depth, lake bottom engineering parameters, extent of ice, navigation pathways, wind speed, important bird habitats, fish efforts and other layers that are relevant for supporting robust offshore wind turbine developments. Additional geospatial products developed during the project included few different prototypes for offshore wind farm suitability which can involve different stakeholders and participants for solving complex planning problems and building consensus. Some of the prototypes include spatial decision support system (SDSS) for collaborative decision making, a web-based Participatory Geographic Information System (PGIS) framework for evaluating importance of different decision alternatives using different evaluation criteria, and an Android application for collection of field data using mobile and tablet devices . In summary, the simulations of two- and three-blade wind turbines suggested that two-bladed machines could produce comparable annual energy as the three-blade wind turbines but have a lighter tower top weight, which leads to lower cost of energy. In addition, the two-blade rotor configuration potentially costs 20% less than a three blade configuration that produces the same power at the same site. The cost model analysis predicted a potential cost savings of approximately 15% for offshore two-blade wind turbines. The foundation design for a wind turbine in Lake Erie is likely to be driven by ice loads based on the currently available ice data and ice mechanics models. Hence, for Lake Eire, the cost savings will be somewhat smaller than the other lakes in the Great Lakes. Considering the size of cranes and vessels currently available in the Great Lakes, the cost optimal wind turbine size should be 3 MW, not larger. The surveillance data from different monitoring systems suggested that bird and bat passage rates per hour were comparable during heavy migrations in both spring and fall seasons while passage rates were significantly correlated to wind directions and wind speeds. The altitude of migration was higher during heavy migrations and higher over water relative to over land. Notable portions of migration on some spring nights occurred parallel the shoreline, often moving perpendicular to southern winds. The birds approaching the Western basin have a higher propensity to cross than birds approaching the Central basin of Lake Erie and as such offshore turbine development might be a better option further east towards Cleveland than in the Western basin. The high stopover density was more strongly associated with migration volume the following night rather than the preceding night. The processed mean scalar wind speeds with temporal resolutions as fine as 10-minute intervals near turbine height showed that August is the month with the weakest winds while December is the month, which typically has the strongest winds. The ice data suggests that shallow western basin of Lake Erie has higher ice cover duration many times exceeding 90 days during some winters.

17 WIND ENERGY↗

Computational Design and Development of a New, Lightweight Cast Alloy for Advanced Cylinder Heads in High-Efficiency, Light-duty Engines

The objective of the collaborative multi-year Cast Lightweight Alloy program was to develop a new, lightweight, cast aluminum alloy for automotive engines with better high temperature properties than the incumbent alloys (B319, A356, A356+0.5Cu) to allow for more efficient engine operation. The program kicked off with the generation of alloy concepts and selecting alloy models with specific milestones for establishing property requirements, generating design concepts and selecting models for casting design. Following this, sub-scale prototypes of the promising design concepts were cast and characterized in order to validate the design concepts and develop data for subsequent model calibration and improvement. Using the calibrated models, a set of alloy designs were created. This first generation set of designs were validated through production and characterization of lab-scale castings. With the learnings from the lab-scale prototypes and the improvements in the computational models, final embodiment design of the new alloy was completed. The final alloy designs were cast at lab-scale and also at component-scale to characterize its final properties. An alloy recyclability analysis and cost modelling was also performed.

36 MATERIALS SCIENCE↗

Sample Testing Basket: Design and Capabilities Report

SFR designs all require integral components that can withstand prolonged submersion in the liquid sodium primary coolant as well as in the gas space of the reactor vessel. Materials are often desired to withstand these conditions for the lifetime of the reactor. The Sample Testing Basket (STB) was designed and fabricated to meet the anticipated need for material exposure testing in prototypic reactor coolant environments; in the liquid sodium primary coolant and the sodium-vapor-laden gas space. Developed at Argonne National Laboratory (ANL), the STB is a piece of equipment designed for use in the Mechanisms Engineering Test Loop (METL) to allow for sodium exposure testing of materials within the METL facility.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

An FPGA-Based Voltage Balancing Control for Multi-HV-IGBTs in Series Connection

The series connection of insulated gate bipolar transistors (IGBTs) allows operation at voltage levels higher than the rated voltage of one IGBT and has less power semiconductor costs compared to multilevel topologies. However, voltage unbalance during the switching transient is a challenge for series-connected device application. This paper presents an field-programmable gate array (FPGA)-based voltage balancing strategy for multiseries-connected high-voltage (HV)-IGBTs including an FPGA-based active voltage balancing control (AVBC) circuit integrated into the gate driver and the control for multiseries-connected IGBTs. As a result, the effectiveness of the control has been experimentally validated in a prototype using four 4.5 kV HV-IGBTs in series connection.

42 ENGINEERING↗

Reliability-Informed Economic and Energy Evaluation for Bi-Level Design for Remanufacturing: A Case Study of Transmission and Hydraulic Manifold

Abstract Design for remanufacturing (DfRem) is one attractive strategy that encourages the reuse of a product and extends the product's life cycle. Traditional design processes often only consider product reliability at an early design stage. However, from the perspective of environmental sustainability, it is becoming increasingly important to evaluate the long-term economic and environmental impacts of design decisions during early-stage design. We propose a bi-level DfRem framework consisting of system-level reusability allocation and component-level design tradeoff analysis, considering reliability and product warranty policy. First, a system-level reusability allocation problem aims at a theoretical exploration of the design space where all the components comprising the system are allocated certain reuse rates to achieve target energy savings with minimum cost. Following the theoretical exploration at the system level, a component-level analysis looks at practical design options for each component and trades-off between the overall cost and energy consumption for multiple remanufacturing cycles. Both levels of the framework require modeling component reuse for multiple remanufacturing cycles, which we achieve by using a branched power-law model that provides probabilistic scenarios of reusing the component or replacing it with a new part. We demonstrate the utility of this framework with the case study of an infinitely variable transmission (IVT) used by some agricultural machines manufactured by John Deere and show snapshots of a prototype software tool that we developed for easy use by designers.

Engineering↗

Turbine Thermal Management (Annual Report)

The FY13 NETL-RUA Turbine Thermal Management effort supported the Department of Energy’s (DOE) Hydrogen Turbine Program through conduct of novel, fundamental, basic, and applied research in the areas of aerothermal heat transfer, coatings development, and secondary flow control. This research project utilized the extensive expertise and facilities readily available at NETL and the participating universities. The research approach included explorative studies based on scaled models and prototype coupon tests conducted under realistic high-temperature, pressurized, turbine operating conditions.

20 FOSSIL-FUELED POWER PLANTS↗

Development and Testing of a Transmission Voltage SuperLimiter™ Fault Current Limiter

This report summarizes work by American Superconductor (AMSC), Los Alamos National Laboratory (LANL), Nexans, Siemens and Southern California Edison on a 138kV resistive type high temperature superconductor (HTS) fault current limiter (FCL) under a cooperative agreement with the U.S. Department of Energy (DOE). Phase 1A encompassed core technology development and system design and was previously reported (see summary that follows in Section 1.1 of the Introduction). This report primarily discusses work performed during Phase 1B, and addresses the fabrication and test of a single-phase prototype FCL. The results are presented along with a discussion of requirements/specifications and lessons learned to aid future development and product commercialization.

42 ENGINEERING↗

Production Facility Prototype Blower 1000 Hour Test Results IV

Long duration operations tests of the Aerzen GM 12.4 roots style blower in a closed loop configuration provides valuable data and lessons learned for long-term operation at the Mo-99 production facility. The blower was operated in a closed loop configuration with the flow conditions anticipated in plant operation with a Mo-100 target inline. The additional thermal energy generated from beam heating of the Mo-100 disks was not included in these tests. Twelve long duration 500 to 1000 hour tests have been completed since the first test was performed in January of 2016. All twelve long duration tests have proven successful in exposing preventable issues related to oil and helium leaks. All blower tests to this date have resulted in stable blower performance and consistency. A summary of the results for the end of the ninth test to the twelfth test is included in this report. Complete details for the previous tests are shown in the reports, Production Facility Prototype Blower 1000 Hour Test Results, II, and III.

42 ENGINEERING↗

Advanced Moderation Module for High-Temperature Micro-Reactor Applications

Development and deployment of micro-reactors that provide competitive efficiency, prevailing compactness, and inherent safety is an immediate focus of the U.S. nuclear industry. For thermal neutron micro-reactors operating at elevated temperature for optimized efficiency, such as micro molten-salt reactors (MSRs), heat-pipe reactors, and very-high temperature reactors (VHTRs), high-performance moderator based on metal hydride can enhance the neutron economy and therefore achieve reduced weight and enhanced portability. As unclad metal hydride inevitably decomposes at elevated temperature, an enclosure is required for hydride moderator to deliver desired performance at elevated temperatures. Conventional moderator enclosure solutions based on high-temperature alloys introduce extraneous neutron penalty into the micro-reactor, affecting the neutronic benefits provided by the hydride moderator. Additionally, the compatibility between the high-temperature alloy enclosure and the micro-reactor matrix is also a potential issue. In this report, we disclose an Advanced Moderator Module (AMM) concept enabled by an innovative enclosure solution combining the advantages of refractory metals, ceramic matrix composites (CMCs), and advanced coating technology to serve as hydrogen permeation barrier up to very-high temperatures. A schematic description of the AMM structure is illustrated in Figure A1. The AMM contains a moderating material core made of metal hydride with high thermal stability, such as YH 2-x . The hydride core is enclosed by an H 2 barrier layer coated on a ductile refractory metal liner to minimize hydrogen loss during high-temperature operation. A ceramic matrix composite (CMC) cladding is adopted to provide further structural strength, especially during power transients. Between the CMC cladding and metal liner, an extra diffusion barrier coating is inserted to suppress the chemical interaction at elevated temperatures. Hence, based on a series of innovative material solutions, the AMM is capable of containing the metal hydride core at elevated temperature (>900oC) inside coated and lined CMC envelop with negligible hydrogen loss throughout the microreactor lifetime. The benefit of the AMM technology was assessed based on a comprehensive multi-stage reactor-physics analysis. Advanced moderation based on hydride metals (such as YH2-x) enables reaching optimum moderation with higher fuel content than traditional VHTR technology, which is required to design compact micro-reactor cores targeting long-life operation. The AMM enclosure technology provides lower thermal neutron absorption rates than traditional solutions (based on stainless steel or Mo-based alloy such as TZM), which reduces the fissile enrichment requirements by 6-8% on a TRISO-fueled design based on the EMPIRE core. Finally, combining the hydride moderator with neutron transparent enclosure solutions provides significant potential to boost neutronics performance of micro-reactors in terms of increased core lifetime or reduced size and weight by 30-50% on a micro-reactor based on the Holos Quad technology. The progress and plans for on-going development and demonstration efforts are also discussed in this report. The current demonstration of AMM is focused on the hydrogen diffusion barrier demonstration under thermal cycling, while radiation tolerance demonstration is planned. The next step of the demonstration plan will be the assembly of miniature AMM for high-temperature testing, which can be used as a prototype for future pilot scale demonstration.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Development of a pixelated BaF 2 test bed for timing applications [Slides]

BaF 2 one of the fastest known scintillators, emitting at 195 & 220 nm with sub-nanosecond decay constant. Fast emission only comprises ~13% of total light. The goal is to develop a prototype BaF 2 detector system with a practical form factor and variable geometry, and characterize system performance for various timing applications.

42 ENGINEERING↗

SAS4A model development for the analysis of postulated severe accidents in metal fuel sodium fast reactors

The SAS4A code has been designed to simulate the events that occur in Sodium Fast Reactor (SFR) during the initiating phase of severe unprotected accidents. The initial SAS4A models were focused on the behavior of oxide fuel cores. An effort to expand the SAS4A models for the analysis of metal fuel cores is currently underway. This paper describes the status of the SAS4A metal fuel model development and presents initial results from the simulation of a postulated fuel assembly blockage accident in the Prototype Gen-IV Sodium Fast Reactor (PGSFR). (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Experimental Investigation of Innovative Cooling Schemes on an Additively Manufactured Engine Scale Turbine Nozzle Guide Vane

This study includes the design, validation, and fabrication via direct metal laser sintering (DMLS) of a gas turbine nozzle guide vanes (NGV) that incorporates three innovative cooling schemes specifically enabled by additive manufacturing. The novel NGV design is the culmination of an extensive research and development effort over a period of 4 years that included low- and high-speed cascade testing coupled with unsteady computational fluid dynamics for numerous candidate innovative cooling architectures. The final vane design (SJ-vane) consists of sweeping jet (SJ) film cooling holes on the suction surface (SS), sweeping jet impingement holes at the leading edge and double-wall partial length triangular pin-fin with impinging jet at the trailing edge. For comparison purposes, a second DMLS enabled vane (777-vane) was designed and fabricated with prototypical cooling circuits to serve as a baseline. This vane consists of a shaped film cooling holes on the suction surface, circular impingement holes at the leading edge, and full-length cylindrical pin-fins at the trailing edge. Experiments with the two DMLS enabled vanes were performed at the Ohio State University Turbine Reacting Flow Rig (TuRFR) at engine-relevant temperature (1375 K) and Mach number conditions. Infrared (IR) thermography was utilized to measure the wall temperature of the pressure and suction surface at several coolant mass flowrates to estimate the overall cooling effectiveness (ϕ). Results showed improved cooling performance for the advanced cooling schemes (sweeping jet film cooling, impingement cooling, and triangular pin-fin cooling) compared with the baseline cooling schemes.

Engineering↗

Hybrid graphene metasurfaces for high-speed mid-infrared light modulation and single-pixel imaging

During the past decades, major advances have been made in both the generation and detection of infrared light; however, its efficient wavefront manipulation and information processing still encounter great challenges. Efficient and fast optoelectronic modulators and spatial light modulators are required for mid-infrared imaging, sensing, security screening, communication and navigation, to name a few. However, their development remains elusive, and prevailing methods reported so far have suffered from drawbacks that significantly limit their practical applications. In this study, by leveraging graphene and metasurfaces, we demonstrate a high-performance free-space mid-infrared modulator operating at gigahertz speeds, low gate voltage and room temperature. Here, we further pixelate the hybrid graphene metasurface to form a prototype spatial light modulator for high frame rate single-pixel imaging, suggesting orders of magnitude improvement over conventional liquid crystal or micromirror-based spatial light modulators. Finally, this work opens up the possibility of exploring wavefront engineering for infrared technologies for which fast temporal and spatial modulations are indispensable.

42 ENGINEERING↗