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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Detection of a Space Capsule Entering Earth’s Atmosphere with Distributed Acoustic Sensing (DAS)

On 24 September 2023, the Origins, Spectral Interpretation, Resource Identification, and Security-Regolith Explorer sample return capsule (SRC) entered Earth’s atmosphere after successfully collecting samples from an asteroid. The known trajectory and timing of this return provided a rare opportunity to strategically instrument sites to record geophysical signals produced by the capsule because it travelled at hypersonic speeds through the atmosphere. For this work, we deployed two distributed acoustic sensing (DAS) interrogators to sample over 12 km of surface-draped fiber-optic cables, as well as six collocated seismometer-infrasound sensor pairs, spread across two sites near Eureka, Nevada. This campaign-style rapid deployment is the first reported recording of an SRC re-entry with any distributed fiber-optic sensing technology. The DAS interrogators recorded an impulsive arrival with an extended coda which had features that were similar to recordings from both the seismometers and infrasound sensors. While the signal-to-noise ratio of the DAS data was lower than the seismic-infrasound data, the extremely dense spacing of fiber-optic sensors allowed for more phases to be clearly distinguished and the visualization of the continuous transformation of the wavefront as it impacted the ground. Unexpectedly, the DAS recordings contain less low-frequency content than is present in both the seismic and infrasound data. The deployment conditions strongly affected the recorded DAS data; in particular, we observed that fiber selection and placement exert strong controls on data quality.

58 GEOSCIENCES↗
DOE OSTI2024

Realization of a gas puff imaging system on the Wendelstein 7-X stellarator

A system for studying the spatiotemporal dynamics of fluctuations in the boundary of the W7-X plasma using the “Gas-Puff Imaging” (GPI) technique has been designed, constructed, installed, and operated. This GPI system addresses a number of challenges specific to long-pulse superconducting devices, such as W7-X, including the long distance between the plasma and the vacuum vessel wall, the long distance between the plasma and diagnostic ports, the range of last closed flux surface (LCFS) locations for different magnetic configurations in W7-X, and management of heat loads on the system’s plasma-facing components. The system features a pair of “converging–diverging” nozzles for partially collimating the gas puffed locally ≈135 mm radially outboard of the plasma boundary, a pop-up turning mirror for viewing the gas puff emission from the side (which also acts as a shutter for the re-entrant vacuum window), and a high-throughput optical system that collects visible emission resulting from the interaction between the puffed gas and the plasma and directs it along a water-cooled re-entrant tube directly onto the 8 × 16 pixel detector array of the fast camera. The DEGAS 2 neutral code was used to simulate the Hα (656 nm) and HeI (587 nm) line emission expected from well-characterized gas-puffs of H2 and He and excited within typical edge plasma profiles in W7-X, thereby predicting line brightnesses used to reduce the risks associated with system sensitivity and placement of the field of view. Operation of GPI on W7-X shows excellent signal-to-noise ratios (>100 at 2 Mframes/s) over the field of view for minimally perturbing gas puffs. The GPI system provides detailed measurements of the two-dimensional (radial and poloidal) dynamics of plasma fluctuations in the W7-X edge and scrape-off layer and in and around the magnetic islands outside the LCFS that make up the island divertor configuration employed on W7-X.

Instruments & Instrumentation↗
DOE OSTI2025

Sensor Placement Optimization Study for the Built Environment: Operational Use Cases

Systems of fixed-position radiation sensors can provide information that assists emergency responders following nuclear and radiological incidents. State, local, tribal, and territorial (SLTT) government agencies that implement systems of fixed-position sensors are faced with numerous decisions regarding sensor selection, quantity, and placement. To develop guidance on implementation of radiation detection systems, we simulated the release of radioactive material in an urban environment using a combination of three models: the Weather Research Forecasting (WRF), Quick Urban and Industrial Complex (QUIC), and Monte Carlo N-Particle (MCNP) models. We then evaluated the performance of several hypothetical sensor systems. The small number of simulations we conducted are not sufficient to generate definitive design guidance for radiation sensor systems, but we did identify trends that would be of interest to emergency planners. For a scenario that releases 1000 curies of Cs-137, radiation detectors were needed at 500-meter intervals to have a high likelihood of event detection and to estimate source location and plume detection. We also noted that optimal detector altitude varied with distance to the source. We recommend additional research in this area be conducted to support developing sensor placement guidelines that expand on a range of locations, isotopes, activity levels, and different weather conditions. Original simulation strategies included a range of environments, additional radioisotopes (Am241 and AmBe), and a larger selection of sensor types. These types of expansions would support SLTT guidance on sensor system recommendations.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Inverse modeling of circular lattices via orbit response measurements in the presence of degeneracy

The number and location of beam position monitors (BPMs) and steerers with respect to the quadrupoles in a circular lattice can lead to degeneracy in the context of fitting linear optics and extracting lattice information from measured closed orbits. Furthermore, the measurement uncertainties due to the imperfection of BPMs and steerers can be propagated by the fitting process in ways that prohibit the successful extraction of discrepancies between lattice elements in the real machine and their description in the corresponding model. We systematically studied the influence of the placement of BPMs and steerers on the reconstruction of linear optics and corresponding lattice information. The derivative of orbit response coefficients with respect to the quadrupole strengths, the Jacobian, is derived as an analytical formula. This analytical version of the Jacobian is used to further derive the theoretical limitations of fitting linear optics from closed orbits in terms of the placement of BPMs and steerers. It is further demonstrated that when evaluating the Jacobian during the fitting procedure, the analytical version can be used in place of the conventional finite-difference computation. This allows for greatly improved efficiency when computing the Jacobian during each iteration of the fitting procedure. The approach is tested with large-scale simulations and the findings are verified by measurement data taken on SIS18 synchrotron at GSI Helmholtz Centre for Heavy Ion Research. The presented methods are of general nature and can be applied to other accelerator lattices as well. The fitting procedure by using the analytical Jacobian is tested in conjunction with various methods for mitigating quasidegeneracy and the results agree with those obtained by using the conventional Jacobian via finite-difference approximation.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Neutron-antineutron oscillation search with MicroBooNE and DUNE

The Deep Underground Neutrino Experiment (DUNE) is an international project aiming at neutrino physics and astrophysics and a search for phenomena predicted by theories beyond the standard model (BSM). The excellent imaging capability of Liquid Argon Time Projection Chamber (LArTPC) technology, particle tracking and identification utilized in the Far Detector, as well as the Far Detector size and underground placement, allow the experiment to achieve high sensitivity to various rare processes. BSM theories predict the existence of baryon number non-conservation effects, in particular when the baryon number changes by 2. Here we discuss the sensitivity of DUNE to neutron-antineutron oscillation. With full event simulation and reconstruction using the LArSoft package, we have investigated the background to potential signal events from atmospheric neutrino interactions and particle misidentification, and utilized machine learning techniques to enhance the discrimination between signal and background. The methodologies being developed for a high-sensitivity search for neutron-antineutron oscillation in DUNE can also be demonstrated with the currently running MicroBooNE LArTPC. We discuss progress on demonstrating the developed techniques with the first-ever search for neutron-antineutron oscillation in a LArTPC using MicroBooNE data.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Improvement of the NOvA Near Detector Event Reconstruction and Primary Vertexing through the Application of Machine Learning Methods

The purpose of this work is to examine the application of a deep learning model in event reconstruction of neutrino interactions. The challenges faced in event reconstruction include the placement of an accurate primary neutrino interaction vertex which is used to support the particle track and prong algorithms. The result of accurate primary vertex ensures all particles involved in a neutrino interaction are included. We propose a regression-based Convolutional Neural Network (CNN) method to predict the primary vertex of a particle interaction. We show that with raw two-dimensional pixel map views as input, the regression-based CNN can predict the primary vertex in all three coordinates. This work is applied as part of the NOvA (NuMI Off-axis $\nu_e$ Appearance) near detector reconstruction efforts. The primary vertex predicted by the regression-based CNN model shows promising results for future applications. This deep learning method can be extended to secondary vertexing through a Kernel Density Estimate algorithm discussed in this work.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

Sensor Placement Optimization Study for the Built Environment: Next Steps Report

Systems of fixed-position radiation sensors can provide information that assists emergency responders following nuclear incidents. First responder organizations that implement systems of fixed-position sensors face numerous decisions regarding sensor selection, quantity, and placement. Researchers at Pacific Northwest National Laboratory (PNNL) have evaluated the performance of several hypothetical sensor systems during a simulated activation of a radiological dispersal device. Due to technical limitations, PNNL’s analysis was limited to a single location and number of scenarios. This document describes additional research and analysis that would result in improved guidance to first responder organizations considering installation of radiation monitoring systems.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Development of an MKID frequency-to-pixel LED mapper for SPT-3G+

SPT-3G+ is the next-generation camera for the South Pole Telescope (SPT). SPT is designed to measure the cosmic microwave background (CMB) and the mm/sub-mm sky. The planned focal plane consists of 34,000 microwave kinetic inductance detectors (MKIDs), divided among three observing bands centered at 220, 285, and 345 GHz. Each readout line is designed to measure 800 MKIDs over a 500 MHz bandwidth, which places stringent constraints on the accuracy of the frequency placement required to limit resonator collisions that reduce the overall detector yield. To meet this constraint, we are developing a two-step process that first optically maps the resonance to a physical pixel location, and then next trims the interdigitated capacitor (IDC) to adjust the resonator frequency. We present a cryogenic LED apparatus operable at 300 mK for the optical illumination of SPT-3G+ detector arrays. We demonstrate integration of the LED controls with the GHz readout electronics (RF-ICE) to take data on an array of prototype SPT-3G+ detectors. We show that this technique is useful for characterizing defects in the resonator frequency across the detector array and will allow for improvements in the detector yield.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2020

Literature Review for Sensor Impact Evaluation and Verification Use Cases - Building Controls and Fault Detection and Diagnosis (FDD)

This report summarizes a comprehensive literature review for the selected sensor suites used in building controls and fault detection and diagnostics (FDD), which is a Q2 deliverable of the Sensor Impact Evaluation and Verification project. The project’s overarching goal is to develop a framework for investigating the impact of sensor deployment and configuration for building energy optimization, fault detection and diagnosis (FDD), occupants’ thermal comfort, and potential grid efficiency. While the first phase of the literature review performed in Q1 reviewed the current methods of various sensor selection and placements and their impact, this report focuses on high impactful potential use cases for the selected sensor suites in building control and FDD. The use cases identified in this literature review will be further investigated and be included in the final sensor impact evaluation framework. For the review, the multi-laboratory team reviewed 241 research papers, technical reports, and books to identify existing technologies, the potential impact on energy savings and thermal comfort, and future research opportunities for the selected use cases in building controls and FDD. Along with the literature review, the team conducted a series of interviews with experts in sensors and controls area to identify the state-of-art sensor technologies, and the most impactful use cases in controls and FDD areas. The interview results will also be incorporated with the findings from the literature review in the next quarter, and the final use cases to be evaluated will be selected.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Synthesis, Processing, and Use of Isotopically Enriched Epitaxial Oxide Thin Films

Isotopic engineering has emerged as a key approach to study the nucleation, diffusion, phase transitions, and reactions of materials at an atomic level. It aims to uncover mass transport pathways, kinetics, and operational and failure mechanisms of functional materials and devices. Understanding these phenomena leads to deeper insights into important physical processes, such as the transport of ions in energy conversion and storage devices and the role of active sites and supports during heterogeneous catalytic reactions. Likewise, isotopic engineering is being pursued as a means of modifying functionality to enable future technological applications. In this Account, we summarize our recent work employing isotope labeling (e.g., 18 O 2 and 57 Fe) during thin film synthesis and postgrowth processing to reveal growth mechanisms, defect chemistry, and elemental diffusion under working and extreme conditions. Isotope-resolved analysis techniques with nanometer-scale spatial resolution, such as time-of-flight secondary ion mass spectrometry and atom probe tomography, facilitate the accurate quantification of isotopic placement and concentration in our well-defined heterostructures with precisely positioned, isotope-enriched layers. By measuring the nanometer-scale redistribution between natural abundance and isotopically enriched oxygen layers during the deposition of Fe 2 O 3 and Cr 2 O 3 by molecular beam epitaxy, we identified intermixing processes driven by surface adatoms occurring both at the film growth surface and within the first few layers below the surface. Further insights into synthesis mechanisms were gained by studying the tungsten oxide thin films grown by evaporating WO 3 powder in the presence of background 18 O 2 , revealing minimal incorporation of background oxygen during the film formation process. Thermal and radiation-enhanced diffusion in epitaxial Fe and Cr oxides were precisely tracked using 18 O and 57 Fe tracer layers incorporated into model epitaxial oxide thin films. This approach has allowed us to access thermal diffusion behavior at lower temperatures than previously measured, revealing a potential changeover in diffusion mechanism. Understanding radiation-enhanced diffusion in model oxides that represent the surface layers on the structural components of nuclear reactors informs our understanding of their corrosion behavior under irradiation. Isotopic labeling can also provide unique insights into the surface exchange reactions and defect chemistry of electrocatalysts. For instance, tracking the change in 18 O concentration at the surface of an epitaxial LaNiO 3 thin film after the electrocatalytic oxygen evolution reaction revealed the participation of lattice oxygen, confirming a hypothesis that had been proposed previously. Lastly, we highlight a new direction wherein we perform in situ processing studies utilizing isotopic tracers in conjunction with model epitaxial thin films within the atom probe tomography instrument. Additionally, this Account illustrates the great potential of isotopic engineering to enable fundamental mechanistic insights into physical processes and engineer functional properties in epitaxial films, heterostructures, and superlattices.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Comparison of Approach-to-Critical Results in Current and Pulse Mode for Systems with High Starter Neutron Rates

Reactors and critical assemblies use a variety of detection systems to monitor the neutron population. The count rate is proportional to the neutron flux present at the location of the detector. When such systems are placed external to an assembly, it is often assumed that the relative leakage multiplication will be proportional to the detector count rate (assuming that the source term, system geometry, and detector placement have not changed). Such systems are often used in an approach-to-critical during reactor startup to ensure that the critical configuration is well predicted. Various types of detectors have been used during an approach-to-critical. These include 3 He, BF 3 , ion chambers, fission chambers, and fission foils. Any of these types of systems (or others) should work well when adequate counting statistics are available. These detector systems can be operated in either pulse or current mode. The National Criticality Experiments Research Center (NCERC) has two detection systems that are commonly used in critical assembly operations. The start-up (referred to as "SU" in this work) system is made up of 3 He proportional counters in pulse mode and the linear counter system (referred to as "LC" in this work) consists of compensated ion-chambers in current mode. Typically the SU system is used for approach-to-critical operations and the LC system is only used at/above delayed critical ( k eff = 1). This work investigates the use of the LC system for an approach-to-critical. It has been long hypothesized that such an approach would be feasible for systems with high starter neutron rates.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Methods for estimating X-ray machine output through measurement and simulation

We report ball grid arrays are increasingly being applied in the electronics industry and may require X-ray inspection to ensure the integrity and correct placement of solder pins. However, as the architecture of integrated circuits continues to narrow while simultaneously growing more complex, the risk of electronic failure due to radiation damage increases. While medical X-ray devices have been held to high standards and are repeatedly shown to be well characterized, devices used for electronic inspection are often lacking detailed characterization. This study presents unique methods to solve for important properties in X-ray inspection devices such as source to object distance and energy spectrum. This information can then be applied to Monte Carlo models to achieve better overall dose estimates to electronics, which will lead to superior manufactured products. Since X-ray devices can vary greatly in source characteristics, this work investigates spectral measurement and Monte Carlo representation of three X-ray devices. For a Philips SRO 33 100 medical diagnostic device, the spectral output followed expected trends given by the prediction software SpekCalc and Spektr. For the Dage XD7500NT, direct measurement showed a spectral artifact that through the use of Gafchromic films, was shown to be a contributing effect in the dose output. For the Rad Source RS1800, a high powered irradiation device, direct spectral measurement was not achieved. However, a Monte Carlo model using an assumed spectra was found to match ion chamber measurements to a high degree.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Advancing Tunnel Detection Via Vertical Acoustic Profiling

This study demonstrates that placing an acoustic source at depth significantly enhances the detection of tunnels. By adapting the methodology of vertical seismic profiling to acoustic-range frequencies, we introduce a novel approach for tunnel detection. To our knowledge, this report documents the first application of this technique. The field study was conducted on a cleared site at the Oak Ridge National Laboratory; the subsurface was clay. A series of vertical shafts were bored immediately before and after the placement of a 40 ft long, 3 ft diameter steel pipe located 10 ft below the surface. Acoustic signatures were produced at various depths up to 30 ft and an array of surface geophones was used to collect the resulting signals. The innovation lies in using subsurface acoustic signatures to better enable the collection of wide-angle diffracted waves by surface geophones. These diffracted waves appear as subharmonic frequencies of the source signal and are recorded by a surface geophone array. While the concept draws from vertical seismic profiling used in oil and gas exploration, a key distinguishing feature is the use of acoustic frequencies, which are necessary for detecting small subsurface features. The findings have important implications. Critical information pertaining to diffracted source signals are not measured by current state-of-the-art methods. Although this study confirms enhanced detectability, accurate localization and imaging will require additional research. Future work should focus on leveraging diffracted-wave strength and time delays to enable full imaging and characterization.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Hybrid Solar System (Final Scientific/Technical Report)

GTI Energy (GTI) teamed with the University of California at Merced (UCM) to scaleup the hybrid solar system (HSS) technology for demonstrating its performance at the US Gypsum (USG) plant in Plaster City, California. The technology integrates two-stage concentrating solar collector with matching particle thermal transport and storage (TSS) system to deliver cost-effective, and on-demand distributed high temperature industrial process heat up to 600°C with solar thermal, in this case to a gypsum kettle, to reduce its fuel use and carbon footprint. Current solar technologies, which reach these temperatures, are not distributable (towers) or cost-effective (dish). The research team developed a conceptual system design for host site retrofit, including preliminary heat balance, process flow diagram, particle to process heat exchanger and equipment placements at the site. Subsequently, parallel efforts were carried out at UCM to design, build and test a 12 m long commercial scale prototype concentrating thermal-only collector system and at GTI to design, build and test a matching 650°C capable particle TTS system. The nominal 50 kWth collector consists of a parabolic trough and three 4 m long two-stage receivers in series. Prior to on-sun testing, a 4 m long receiver was fabricated and successfully tested at 650 °C in a laboratory setting for 100 hrs of continuous operation showing less than 15% radiation loss. A 7 m wide x 17 m long parabolic trough was then installed at UCM for on-sun testing of the 12 m long receiver, and concurrently several 4 m long receivers were built. The optics of the parabolic trough were calibrated, and on-sun test were carried out on 12 m long receivers. During tests, the intense solar radiation (53x) caused the absorber tubes in the receivers to bend, reducing the overall optical efficiency. To address the bending issue, a self-consistent algorithm that includes ray tracing, thermal and deformation models was developed to perform thermal stress analysis on absorbers for parabolic solar collectors. Results obtained with this algorithm showed a dramatic rise in deformation as absorber tube length increases. A combined efficiency parameter that includes the occluded area for the mounts was developed to obtain an optimized tube length obtained. Based on the results, a length of 2.7 m for the absorber + 0.2 m for the coupler was chosen to minimize any bending and optimize optical efficiency while maintaining ease of mounting. The associated particle TTS system was designed, built and successfully tested at GTI. It includes storage, receiving and lock hoppers and piping that simulates the transfer of captured solar energy to an actual industrial furnace. Tests over 77 charge-discharge cycles demonstrated <2% particle degradation, with no problematic particle accumulations and no flow interruptions. The piping pressure drop was about 5 psi. The team also worked with Stanley Consultants (Stanley) to prepare conceptual and preliminary engineering packages to facilitate follow-on development and commercialization efforts. These include process and instrumentation diagram’s (P&ID’s), general arrangements, electrical one-line, project definitions document, equipment data sheets, schedule, and construction cost estimate for 2 MWth system. Updated HSS technology commercialization and customer engagement plans and detailed costs and evaluated market trade-offs and manufacturing.

03 NATURAL GAS↗
DOE OSTI2025

Flow and thermal modelling of the argon volume in the DarkSide-20k TPC

The DarkSide-20k dark matter experiment, currently under construction at LNGS, features a dual-phase time projection chamber (TPC) with a ∼ 50 t argon target from an underground well. At this scale, it is crucial to optimise the argon flow pattern for efficient target purification and for fast distribution of internal gaseous calibration sources with lifetimes of the order of hours. To this end, we have performed computational fluid dynamics simulations and heat transfer calculations. The residence time distribution shows that the detector is well-mixed on time-scales of the turnover time (∼ 40 d). Notably, simulations show that despite a two-order-of-magnitude difference between the turnover time and the half-life of 83m Kr of 1.83 h, source atoms have the highest probability to reach the centre of the TPC 13 min after their injection, allowing for a homogeneous distribution before undergoing radioactive decay. We further analyse the thermal aspects of dual-phase operation and define the requirements for the formation of a stable gas pocket on top of the liquid. We find a best-estimate value for the heat transfer rate at the liquid-gas interface of 62 W with an upper limit of 144 W and a minimum gas pocket inlet temperature of 89 K to avoid condensation on the acrylic anode. This study also informs the placement of liquid inlets and outlets in the TPC. The presented techniques are widely applicable to other large-scale, noble-liquid detectors.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

A Review of Existing Test Methods for Occupancy Sensors

One of the key new features of connected lighting systems (CLS) is their ability to collect data from various types of integral sensors and share that data with other lighting or building systems. Occupancy and vacancy sensors have been widely adopted as an energy-saving strategy in buildings, yet published test methods for reproducibly characterizing their performance remain few and limited in their sophistication. As a result, it has been difficult to predict their performance in a specific application, and in practice, they frequently do not meet energy-savings expectations. Occupants at times remove or otherwise bypass occupancy sensors that hinder their work or otherwise do not perform as expected, thereby compromising the sensors’ potential to reduce energy consumption. Poor performance can result from multiple causes – ranging from fundamental limitations of the sensor technology, to misconfiguration, to poor placement in the room or space. Innovative occupancy sensors, some of them combining multiple sensing technologies, have come on the market over the years, with claims of improved performance compared to their predecessors; yet in practice, their performance has led to neither high deployment nor high user satisfaction in any significant application, nor has it differed enough from the performance of previous products to necessitate a test method that facilitated comparison between them. While the performance of both common and novel occupancy sensors has been the subject of many published research articles, the test methods that have been employed for them have typically been loosely described and incorporated custom equipment or techniques that render them difficult to reproduce, or have been limited in their ability to fairly characterize devices that utilize varying sensor technology. The lack of a well-described, technology-agnostic test method that yields reproducible results across different implementations has been a barrier to the commercial success of new occupancy sensor products, as users and specifiers who have been disappointed with previous products are often unwilling to take a chance with new ones. Motivated by a desire to fairly characterize new technologies that continue to enter the market and claim not only improved occupancy detection but, in some cases, also additional capabilities (e.g., the ability to measure traffic or discern between different object types), this report presents the results of a literature review of recent published, well-described test methods for characterizing occupancy sensor performance, as well as research articles containing ad-hoc test methods. The review also identifies and consolidates the best techniques for characterizing sensor performance in indoor spaces and identifies test method gaps that need to be filled in order to evaluate emerging technologies and products.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Thermopile Energy Harvesting for Subsurface Wellbore Sensors (Final Report)

Robust in situ power harvesting underlies all efforts to enable downhole autonomous sensors for real-time and long-term monitoring of CO 2 plume movement and permeance, wellbore health, and induced seismicity. This project evaluated the potential use of downhole thermopile arrays, known as thermoelectric generators (TEGs), as power sources to charge sensors for in situ real-time, long-term data capture and transmission. Real-time downhole monitoring will enable “Big Data” techniques and machine learning, using massive amounts of continuous data from embedded sensors, to quantify short- and long-term stability and safety of enhanced oil recovery and/or commercial-scale geologic CO 2 storage. This project evaluated possible placement of the TEGs at two different wellbore locations: on the outside of the casing; or on the production tubing. TEGs convert heat flux to electrical power, and in the borehole environment, would convert heat flux into or out of the borehole into power for downhole sensors. Such heat flux would be driven by pumping of cold or hot fluids into the borehole—for instance, injecting supercritical CO 2 —creating a thermal pulse that could power the downhole sensors. Hence, wireless power generation could be accomplished with in situ TEG energy harvesting. This final report summarizes the project’s efforts that accomplished the creation of a fully operational thermopile field unit, including selection of materials, laboratory benchtop experiments and thermal-hydrologic modeling for design and optimization of the field-scale power generation test unit. Finally, the report describes the field unit that has been built and presents results of performance and survivability testing. The performance and survivability testing evaluated the following: 1) downhole power generation in response to a thermal gradient produced by pumping a heated fluid down a borehole and through the field unit; and 2) component survivability and operation at elevated temperature and pressure conditions representative of field conditions. The performance and survivability testing show that TEG arrays are viable for generating ample energy to power downhole sensors, although it is important to note that developing or connecting to sensors was beyond the scope of this project. This project’s accomplishments thus traversed from a low Technical Readiness Level (TRL) on fundamental concepts of the application and modeling to TRL-5 via testing of the fully integrated field unit for power generation in relevant environments. A fully issued United States Patent covers the wellbore power harvesting technology and applications developed by this project.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Application and Certification of Comparative Vacuum Monitoring Sensors for Structural Health Monitoring of 737 Wing Box Fittings

Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today's extensive fleet of aging aircraft and space vehicles. The use of in-situ sensors for real-time health monitoring of aircraft structures are a viable option to overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. Prevention of unexpected flaw growth and structural failure can be improved if on-board health monitoring systems are used to continuously assess structural integrity. Such systems are able to detect incipient damage before catastrophic failures occurs. Condition-based maintenance practices could be substituted for the current time-based maintenance approach. Other advantages of on-board distributed sensor systems are that they can eliminate costly, and potentially damaging, disassembly, improve sensitivity by producing optimum placement of sensors and decrease maintenance costs by eliminating more time- consuming manual inspections. This report presents a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Boeing, Delta Air Lines, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp. and the Federal Aviation Administration (FAA) carried out a certification program to formally introduce Comparative Vacuum Monitoring (CVM) as a structural health monitoring solution to a specific aircraft wing box application. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM into an airline maintenance program and the document revisions necessary to allow for routine use of CVM as an alternate means of performing periodic structural inspects. To carry out the validation process, knowledge of aircraft maintenance practices was coupled with an unbiased, independent evaluation. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically-relevant experimental effort to quantify the reliability of the CVM system applied to the Boeing 737 Wing Box fitting application. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for CVM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and also is acceptable to both the aviation industry and regulatory bodies. This report presents the use of several different statistical methods, some of them adapted from NDI performance assessments and some proposed to address the unique nature of damage detection via SHM systems, and discusses how they can converge to produce a confident quantification of SHM performance An important element in developing SHM validation processes is a clear understanding of the regulatory measures needed to adopt SHM solutions along with the knowledge of the structural and maintenance characteristics that may impact the operational performance of an SHM system. This report describes the major elements of an SHM validation approach and differentiates the SHM elements from those found in NDI validation. The activities conducted in this program demonstrated the feasibility of routine SHM usage in general and CVM in particular for the application selected. They also helped establish an optimum OEM-airline-regulator process and determined how to safely adopt SHM solutions. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM technology. It will also streamline the regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗