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This document is a resource for ongoing work. This describes calculations for error propagation and test uncertainty of the LANL FTS Filter Test System for nuclear storage containers.
LANL has purchased “Hagan” canisters and “SAVY” canisters from NFT Inc (Golden CO). This document provides instruction for calibrating a LANL-designed FTS Filter Test System. The FTS device measures the amount of oil droplet aerosol captured in filters of nuclear material canisters at Los Alamos National Laboratory (LANL). The FTS device is intended to evaluate canister filters manufactured by NFT. The Los Alamos Standards and Calibration Lab (S&CL) does not support the calibration of aerosol generation or counting instrumentation. For operations inside the LANL TA-55 PF4 facility, the LANL FTS system could be potentially contaminated. LANL has constructed two (2) FTS devices, one in TA-55, the other in TA-3.
Idaho National Laboratory (INL) is designing a Dynamic Energy Transport and Integration Laboratory (DETAIL) to demonstrate the operation of an integrated energy system as part of supporting research and development needs for the DOE Office of Nuclear Energy Integrated Energy Systems (IES) Program. DETAIL will demonstrate real-time integration with the electrical grid, renewable energy inputs, thermal and electrical energy storage, and energy delivery to an end user. A Thermal Energy Distribution System (TEDS) is being constructed within the DETAIL facility to demonstrate the operation of integrated energy system heat transfer components, thermal energy storage, distribution systems, and instrumentation and control (I&C), which will allow the facility to emulate the distribution of thermal energy to the generation of electrical power, and/or producing non-electrical commodities (e.g., hydrogen). As is the case for other subsystems within DETAIL, TEDS is designed to operate either independently or as a part of an integrated system to demonstrate the operation of integrated components, develop and validate thermal energy transport models and control systems, and study thermal energy inertia and energy storage. In an effort to completely understand how TEDS will integrate with operational plants, data from tests previously run at existing integral system test facilities (IST) will be used to drive the TEDS heater. Alternatively, a real-time data connection would allow steam conditions at the IST to drive the TEDS heater at the same time as having TEDS conditions provide feedback to the IST in terms of steam demand and/or pressure. This integrated testing approach will assess the ability of TEDS to operate during all plant conditions. Three existing integral system test facilities have been reviewed to determine their suitability for demonstrating TEDS capabilities when integrated within the DETAIL. This report summarizes the capabilities of each IST facility and any challenges that must be overcome to meet the operational needs of TEDS and DETAIL.
The purpose of this procedure is to measure the collection efficiency of the filters that are integrated into the lids of containers for nuclear material at Los Alamos National Laboratory (LANL). As an application of this procedure, a filter test report certificate can be created to document the measurement process. This procedure is intended to describe the TA-55, PF-4 (room 6A) operation of a Filter Test System (FTS) for Hagan and SAVY storage containers.
This report details the design of a test stand that converts carbon dioxide and hydrogen into methanol via a two-step process. The first step is a reverse water-gas shift reaction, carried out at 600°C and 25 bar to reduce carbon dioxide to carbon monoxide, and the second is a synthesis reaction that forms methanol at 260°C and 75 bar. The purpose of the system is to test catalysts for each of these steps. The test stand produces approximately 1.5 gallons of crude methanol (methanol mixed with water) per day, and recycles unreacted syngas for increased efficiency. At peak recycle, the stand is expected to consume 0.29 cylinders per day of carbon dioxide and 1.43 cylinders per day of hydrogen. It is planned to be built next to the Blue Star electrolysis unit in the Energy Systems Laboratory (ESL) and includes future plans of acquiring hydrogen from that stand rather than gas cylinders. At this phase of research, three key documents have been produced, as summarized in Table 1. These documents are primarily intended to describe the system and its operation, demonstrate that selected components are appropriate for the intended application, identify potential hazards, safeguards, and mitigation strategies, and ensure that the system is designed to appropriate standards. The body of the report and its appendices provide a narrative of the work completed in FY25. The parts required to build the test stand will be procured and assembled in FY26. Testing will be conducted in the final quarter.
In the development of a digital twin (DT) for hydropower turbines, dynamic modeling of the system (e.g., penstock, turbine, speed control) is crucial, along with all the necessary data interface, virtualization, and dashboard designs. Since the DT must mimic the actual dynamics of the hydropower turbine accurately, adaptive learning is required to train these dynamic models online so that the models in the DT can effectively follow the representation of the actual hydropower turbine dynamics accurately and reliably. This study presents an adaptive learning method for obtaining the hydropower turbine models for DT development of hydropower systems using the recursive least squares algorithm. To simplify the formulation, the hydropower turbine under consideration was assumed to operate near a fixed operating point, where the system dynamics can be well represented by a set of linear differential equations with constant parameters. In this context, the well-known six-coefficient model for the Francis turbine was formulated as the starting point to obtain input and output models for the turbine. Then, an adaptive learning mechanism was developed to learn model parameters using real-time data from a hydropower turbine testing system. This led to semi-physical modeling, in which first principles and data-driven modeling are integrated to produce dynamic models for DT development. Applications to a pilot system at the Norwegian University of Science and Technology (NTNU) were made, and the models learned adaptively using the data collected from the university’s pilot system. Desired modeling and validation results were obtained.
A new generation of Concentrating Solar Power (CSP) technologies is under development to provide dispatchable renewable power generation and reduce the levelized cost of electricity (LCOE) to 6 cents/kWh by leveraging heat transfer fluids (HTF) capable of operation at higher temperatures and coupling with higher efficiency power conversion cycles. The U.S. Department of Energy (DOE) has funded three pathways for Generation 3 CSP (Gen3CSP) technology development to leverage solid, liquid, and gaseous HTFs to transfer heat to a supercritical carbon dioxide (sCO 2 ) Brayton cycle. Here we present the design and off-design capabilities of a 1 MWth sCO 2 test system that can provide sCO 2 coolant to the primary heat exchangers (PHX) coupling the high-temperature HTFs to the sCO 2 working fluid of the power cycle. This system will demonstrate design, performance, lifetime, and operability at a scale relevant to commercial CSP. A dense-phase high pressure canned motor pump is used to supply up to 5.3 kg/s of sCO 2 flow to the primary heat exchanger at pressures up to 250 bar and temperatures up to 715 °C with ambient air as the ultimate heat sink. Key component requirements for this system are presented in this paper.
The lifecycle of radiation detection systems functioning within a State’s Nuclear Security Detection Architecture encompasses all activities associated with acquisition, deployment, and eventual disposal. Throughout a system’s lifecycle, testing and evaluation activities are needed to ensure requirements are continually met, as underscored by recent experiences.This paper provides:1.A discussion of reasons why testing should be part of the radiation detection equipment lifecycle before, during, and after acquisition.2.A general process for determining applicable evaluation methods.3.A discussion of issues related to integrating testing and evaluation into procurement and operational processes and mitigation strategies.
The immobilized low-activity waste (ILAW) transportation system is a first-of-a-kind system that is being designed and tested to transport ILAW glass-filled containers from Hanford's Waste Treatment and Immobilization Plant (WTP) Low-Activity Waste (LAW) Facility to the Integrated Disposal Facility (IDF) burial trench for permanent disposal. A prototype design and fabrication of one transport trailer and four engineered ILAW pallets was completed in mid-2018. Prototype qualification testing to verify adequacy of the design was completed in 2019 by Washington River Protection Solutions (WRPS) and affiliate ATKINS SNC-Lavalin Group. Prototype testing was completed to advance design maturation across all operational and facility interfaces, and under adverse environmental and operating conditions, including thermal assessment of the system at peak projected temperatures. Test design, observation, and feedback was well represented and supported by all ILAW Transportation System interfacing organizations: WTP constructor Bechtel National, Inc.; IDF operator CH2M (CHPRC); transportation contractor Mission Support Alliance (MSA); the U. S. Department of Energy Richland Operations Office (DOE/RL) and Office of River Protection (DOE/ORP); and Washington State Department of Ecology. This paper presents the results of prototype qualification testing and opportunities for design improvements based on testing. Changes to the final design as a result of prototype testing include improvements in safety, ergonomics, operational flexibility, and As-Low-As-Reasonably-Achievable (ALARA) applications. (authors)
A MARVEL thermal-hydraulic analysis team has developed the computational fluid dynamicsmodel of the Primary Coolant Test (PCAT) system design based on the CAD drawing providedfrom INL PCAT design team. This ECAR addresses the hydraulic system characteristics(pressure loss and flow distribution) in the various sub-components of the PCAT design. Thisreport provides potential design optimization direction on the PCAT test. Most importantly, thisreport evaluates the feasibility of the natural circulation at the targeted heat balance between thecore and heat sink design.
Abstract This study evaluated a multi-catenary spread mooring system design of a mobile ocean test berth for wave energy converters (WECs), the Ocean Sentinel (OS) instrumentation buoy, through dynamic simulation, numerical analysis, and comparison with measured field motion data of the OS off the OR coast. First, the accuracy of the numerical employed model based on a fully-coupled method of the OS and its mooring lines was validated by comparing predicted mooring tensions to the field measurements. Then, the anchor movability, fatigue damage, and extreme mooring tension of the OS mooring system were analyzed to assess survivability. Field test results show that the numerical model provided accurate predictions of mooring tensions even under environmental conditions of strong wind, current, and waves. Factors affecting the accuracy are discussed. One mooring anchor was shown to have moved significantly during the ocean field test. Mooring fatigue damage was calculated for different levels of sea states. Design strengths of the mooring lines were calculated and analyzed.
While the field of wave energy has been the subject of numerical simulation, scale model testing, and precommercial project testing for decades, wave energy technologies remain in the early stages of development and must continuing proving themselves as a promising modern renewable energy field. One of the difficulties that wave energy systems have been struggling to overcome is the design of highly efficient energy conversion systems that can convert the mechanical power, derived from the oscillation of wave activated bodies, into another useful product. Often the power take-off (PTO) is defined as the single unit responsible for converting mechanical power into another usable form such as electricity, pressurized fluid, compressed air, and others. The PTO, and the entire power conversion chain (PCC), is of great importance as it affects not only how efficient wave power is converted into electricity, but also contributes to the mass, size, structural dynamics, and levelized cost of energy (LCOE) of the wave energy converter (WEC). Unlike wind and solar, there is no industrial standard device, or devices, for wave energy conversion and this diversity is transferred to the PTO system. The majority of current WEC PTO systems incorporate a mechanical or hydraulic drive train, power generator, and an electrical control system. The challenge of WEC PTO designs is designing a mechanical-to-electrical component that can efficiently convert irregular, bi-directional, low frequency and low alternating velocity wave motions. While gross average power levels can be predicted in advance, the variable wave elevation input has to be converted into smooth electrical output and hence usually necessitates some type of energy storage system, such as battery storage, accumulator super capacitors, etc., or other means of compensation such as an array of devices. One of the primary challenges for wave energy converter systems is the fluctuating nature of wave resources, which require WEC components to be designed to handle loads (i.e. torques, forces, and powers) that are many times greater than the average load. This approach requires a much greater PTO capacity than the average power output and indicates a higher cost. In addition, supporting mechanical coupling and or gearing can be added to the PCC to help alleviate the difficulties with transmission and control of fluctuating large loads with low frequencies (indicative of wave forcing) into smaller loads at higher frequencies (optimum for conventional electrical machine design) can quickly increase the complexity of the PCC which could result in a greater number of failure modes and increased maintenance costs. All of the previous points demonstrate how the PTO influences WEC dynamics, reliability, performance and cost which are critical design factors. This paper further explores these topics by providing a review of the state-of-the-art PTO systems currently under development, how these novel PTO systems are tested and derisked prior to precommercial deployment, and the evaluation metrics historically used to differentiate between PTO designs and how they can be improved to support control co-design focused development of wave energy systems.
The goal of this U.S. Department of Energy (DOE) sponsored project is to test a 200 kWe thermally self-sustaining atmospheric-pressure solid oxide fuel cell (SOFC) prototype system at a prominent site. Fuel Cell Energy Inc. (FCE) utilized the state-of-the-art SOFC technology of its wholly-owned subsidiary Versa Power Systems (VPS) to design, fabricate and test the 200 kW prototype system. The specific objectives of this project were to achieve an SOFC stack power degradation rate of ≤1.5% per 1000 hours for the 400 kW stand-alone prototype power system undergoing ≥ 5000 hours of steady state tests at thermally self-sustained normal operating conditions (NOC), and to verify the prospects for a high volume SOFC stack production cost below the DOE target of 225 dollars per kilowatt. Achieving these goals enables commercial natural gas fueled SOFC system deployment in the 2020 timeframe, which will eventually lead to SOFC technology that is viable for large scale central power generation applications.
This poster presents a high-level review of the U.S. Department of Energy, Office of Electricity Delivery and Energy Reliability, Advanced Distribution Management System Program and test bed development.
The long-term operation (LTO) of nuclear power plant (NPP) beyond their original design life of 40 years, can lead to more material damage associated with cyclic fatigue under thermal-mechanical loading cycles and associated long-term exposure of reactor material to the deleterious reactor-coolant environments. However, under this LTO condition the reactor components can still safely operate but may require more frequent Nondestructive Evaluation (NDE) of reactor components. Frequent NDE requirement may lead to frequent shutdown of the NPP. This in turn can lead to power outage and additional NDE-inspection-cost related economic loss. The economic loss can be minimized by reducing uncertainty in life estimation of safety-critical pressure boundary components and by implementing more digital approach such as by using upcoming digital-twin (DT) technology for predicting the structural states (e.g., time and location dependent inside/outside thickness temperature, stress, strain, plastic deformation, etc.) and associated fatigue life of a component in real time. Towards this goal Argonne National Laboratory (ANL) with the sponsorship of DOE Light Water Reactor Sustainability (LWRS) program is working on the development of a DT framework that can be used for real time environmental fatigue prediction of reactor components. The DT framework is based on limited experiment-data, Artificial-intelligence (AI) – Machine-Learning (ML) - Deep-Learning (DL) based techniques and Multiphysics-computational-mechanics such as finite element (FE) based modeling tools. Towards this overall goal, following are some of the major contributions made during the FY21: 1) Multiple 82/182 dissimilar metal weld (DMW) specimens (both solid-weld and joint-weld representing the actual reactor multi-metal nozzles) were fatigue tested. The resulting fatigue lives were compared to the NUREG-6909 based best-fit and design fatigue curves. Additionally, the results of 52/152 DMW fatigue specimens (which were recently tested at Republic of Korea under the sponsorship of International Nuclear Energy Research Initiative - INERI program) were compared to the NUREG-6909 based best-fit and design fatigue curves. From the comparison of 82/182 and 52/152 DMW test data with NUREG-6909 best-fit curve, most of the reported test data fall way away from the NUREG-6909 suggested best-fit or mean curve. The NUREG-6909 suggested best-fit curve is the best-fit curve of austenitic stainless steel and due to lack of enough data on Nickel-based welds, this is currently being used for predicting the life of Nickel-alloy-based welded components. However, the above observation may require higher scaling factor (e.g., ASME suggested factor of 20 on cycles rather than the current NUREG-6909 suggested factor of 12 on cycles) for scaling the austenitic-stainless-steel best-fit-curve for estimating the design or safe-life of a welded component. Accordingly, for example, if a DMW component experience a strain amplitude of 0.6% the PWR-water life of the component would be 52 cycles instead of 85 cycles. However, more DMW tests are required to further ascertain the above-mentioned observations. 2) A system level CAD and finite element model were developed which consists of reactor pressure vessel (RPV), part of steam generator (SG), part of pressurizer (PRZ), hot leg (HL), and surge line (SL). This is with detailed nozzle geometry and thermal-mechanical material properties of different metals to simulate realistic thermal-mechanical stress under connected system global thermal-mechanical boundary conditions. 3) Different system level heat transfer analyses were performed with estimation of relevant heat transfer coefficients. The resulting data were used in subsequent system level thermal-mechanical stress analysis and for generating spatial-temporal training and validation data for a system level digital-twin based temperature predictor. Transient heat transfer analyses were performed considering thermal boundary condition under design-basis (DB) loading and EDF (Électricité de France) data-based grid-load-following (EDF-GLF) loading cycles. 4) System level thermal-mechanical stress analysis was performed for identifying damage-prone hotspots and for future extension of the model for cyclic state prediction. From the system-level model simulation under DB loading cycle it is found that HL and the SL nozzle that connect to the HL can experience significant stress and strain and could be one of the weakest links in the overall reactor coolant system (RCS). 5) An AI/ML based DT model was developed for multi-time-series temperature prediction at any inside/outside thickness locations of PWR pressure boundary components. This is by using Recurrent-neural-network (RNN) and keras machine learning libraries. The RNN model was validated against two laboratory test-based data sets with one obtained through ANL’s in-air fatigue test system and other through PWR-water test loop. The experimentally validated DT model further validated against FE model results to predict thermal scarification related spatialtemporal temperatures at random locations of a component. The well validated DT model was then used for demonstrating spatial-temporal temperature prediction under 100+ years of reactor operation subjected to combined DB, EDF-GLF and randomized grid-load-following (RANDOMGLF) loading Cycles. The expert-elicitation DT model framework was developed assuming field/input/process measurements can be available from a few existing plant sensors and can readily be used by the NPP operators. The above temperature prediction model will feed to the next-step stress analysis model based on which the life of a component can be predicted in realtime, which is one of our future works.
The Cryomodules (CM) for the Linear Coherent Light Source II (LCLS-II) will be shipped to SLAC (Menlo Park, California) from JLab (Newport News, Virginia) and FNAL (Batavia, Illinois). A transportation system has been designed and built to safely transport the CMs over the road. It uses an array of helical isolator springs to attenuate shocks on the CM to below 1.5g in all directions. The system rides on trailers equipped with Air-Ride suspension, which attenuates vibration loads. The prototype LCLS-II CM (pCM) was driven 750 miles to test the transport system; shock loggers recorded the shock attenuation on the pCM and vacuum gauges were used to detect any compromises in beamline vacuum. Alignment measurements were taken before and after the trip to check whether cavity positions had shifted beyond the ± 0.2mm spec. Passband frequencies and cavity gradients were measured at 2K at the Cryomodule Test Facility (CMTF) at JLab to identify any degradation of CM performance after transportation. The transport system was found to have safely carried the CM and is cleared to begin shipments from JLab and FNAL to SLAC.
In this paper, we present a test bed for evaluating existing and future advanced distribution management system (ADMS) applications in a realistic laboratory setting, including other utility management systems and field equipment. We present an example of using it to evaluate the impact of the ADMS network model quality on a Volt/VAR optimization (VVO) application. The test bed integrates a commercial ADMS with a real-time simulation model of a utility distribution feeder. Representative power and controller hardware are integrated through hardware-in-the-loop (HIL) techniques. The performance of the ADMS VVO application is also evaluated for different levels of measurement density. Initial results indicate that a higher model quality achieves the highest possible energy savings while avoiding voltage violations, whereas a lower model quality results in increased energy savings but at the expense of more voltage violations.
A constant pressure, mixed gas permeation testing skid was deployed at the National Carbon Capture Center to test membrane performance when continuously exposed to slipstream post-combustion flue gas. Small, laboratory scale membranes can be loaded for testing and the degree of automation allowed the skid to be run unattended for several weeks at a time. In this report, we share our experience in commissioning the skid and quantifying CO 2 , N 2 and O 2 permeances of several membranes during the first round of testing. Dense films of polydimethylsiloxane and poly(bistrifluoroethoxyphosphazene) were tested with flue gas for approximately 20 h each. Here, in addition, we successfully tested four thin film composite hollow fiber membranes made by a dip coating process, consisting of porous Torlon hollow fibers coated with a selective layer of poly(bistrifluoroethoxyphosphazene) or its mixed matrix with a metal organic framework SIFSIX-Cu-2i filler particles. Initial results suggest the polydimethylsiloxane showed comparable results to the literature data, but the coated hollow fiber membranes have lower CO 2 permeances relative to N 2 or O 2 permeances compared to their performance under idealized, dry, contaminant-free mixed gas conditions. While quantification of H 2 O permeance was performed, we found it was affected by concentration polarization even with small membrane area and a low stage cut.