Results for “Process Control” — Page 33

DOE OSTI2012

Testing Dual Rotary Filters - 12373

The Savannah River National Laboratory (SRNL) installed and tested two hydraulically connected SpinTek{sup R} Rotary Micro-filter units to determine the behavior of a multiple filter system and develop a multi-filter automated control scheme. Developing and testing the control of multiple filters was the next step in the development of the rotary filter for deployment. The test stand was assembled using as much of the hardware planned for use in the field including instrumentation and valving. The control scheme developed will serve as the basis for the scheme used in deployment. The multi filter setup was controlled via an Emerson DeltaV control system running version 10.3 software. Emerson model MD controllers were installed to run the control algorithms developed during this test. Savannah River Remediation (SRR) Process Control Engineering personnel developed the software used to operate the process test model. While a variety of control schemes were tested, two primary algorithms provided extremely stable control as well as significant resistance to process upsets that could lead to equipment interlock conditions. The control system was tuned to provide satisfactory response to changing conditions during the operation of the multi-filter system. Stability was maintained through the startup and shutdown of one of the filter units while the second was still in operation. The equipment selected for deployment, including the concentrate discharge control valve, the pressure transmitters, and flow meters, performed well. Automation of the valve control integrated well with the control scheme and when used in concert with the other control variables, allowed automated control of the dual rotary filter system. Experience acquired on a multi-filter system behavior and with the system layout during this test helped to identify areas where the current deployment rotary filter installation design could be improved. Completion of this testing provides the necessary information on the control and system behavior that will be used in deployment on actual waste. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2015

Observing the Growth of Metal-Organic Frameworks by In-Situ Liquid Cell Transmission Electron Microscopy

Liquid Cell Transmission Electron Microscopy (LCTEM) can provide direct observations of solution phase nanoscale materials, and holds great promise as a tool for monitoring dynamic self assembly processes. Control over particle behavior within the liquid cell, and under electron beam irradiation, is of paramount importance for this technique to contribute to our understanding of chemistry and materials science at the nanoscale. However, this type of control has not been demonstrated for complex, organic macromolecular materials, which form the basis for all biological systems, all of polymer science, and encompass important classes of advanced porous materials. Here we show that by controlling the liquid cell surface chemistry and electron beam effects, the dynamics and self-assembly of metal-organic frameworks (MOFs) can be observed. Our results demonstrate that hybrid organic/inorganic beam sensitive materials can be analyzed with LCTEM and at least in the case of Zif-8 dynamics, the results correlate with observations from bulk growth or other standard synthetic conditions. We anticipate that direct, nanoscale imaging by LCTEM of MOF nucleation and growth mechanisms, may provide insight into controlled MOF crystal morphology, domain composition, and processes influencing defect formation.

Environmental Molecular Sciences Laboratory↗

DOE OSTI2017

Defense waste processing facility (DWPF) liquids model: revisions for processing higher TIO 2 containing glasses

Radioactive high level waste (HLW) at the Savannah River Site (SRS) has successfully been vitrified into borosilicate glass in the Defense Waste Processing Facility (DWPF) since 1996. Vitrification requires stringent product/process (P/P) constraints since the glass cannot be reworked once it is poured into ten foot tall by two foot diameter canisters. A unique “feed forward” statistical process control (SPC) was developed for this control rather than statistical quality control (SQC). In SPC, the feed composition to the DWPF melter is controlled prior to vitrification. In SQC, the glass product would be sampled after it is vitrified. Individual glass property-composition models form the basis for the “feed forward” SPC. The models transform constraints on the melt and glass properties into constraints on the feed composition going to the melter in order to guarantee, at the 95% confidence level, that the feed will be processable and that the durability of the resulting waste form will be acceptable to a geologic repository. This report documents the development of revised TiO 2 , Na 2 O, Li 2 O and Fe 2 O 3 coefficients in the SWPF liquidus model and revised coefficients (a, b, c, and d).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2014

MO-A-16A-01: QA Procedures and Metrics: In Search of QA Usability

Radiation therapy has undergone considerable changes in the past two decades with a surge of new technology and treatment delivery methods. The complexity of radiation therapy treatments has increased and there has been increased awareness and publicity about the associated risks. In response, there has been proliferation of guidelines for medical physicists to adopt to ensure that treatments are delivered safely. Task Group recommendations are copious, and clinical physicists' hours are longer, stretched to various degrees between site planning and management, IT support, physics QA, and treatment planning responsibilities.Radiation oncology has many quality control practices in place to ensure the delivery of high-quality, safe treatments. Incident reporting systems have been developed to collect statistics about near miss events at many radiation oncology centers. However, tools are lacking to assess the impact of these various control measures. A recent effort to address this shortcoming is the work of Ford et al (2012) who recently published a methodology enumerating quality control quantification for measuring the effectiveness of safety barriers. Over 4000 near-miss incidents reported from 2 academic radiation oncology clinics were analyzed using quality control quantification, and a profile of the most effective quality control measures (metrics) was identified.There is a critical need to identify a QA metric to help the busy clinical physicists to focus their limited time and resources most effectively in order to minimize or eliminate errors in the radiation treatment delivery processes. In this symposium the usefulness of workflows and QA metrics to assure safe and high quality patient care will be explored.Two presentations will be given:Quality Metrics and Risk Management with High Risk Radiation Oncology ProceduresStrategies and metrics for quality management in the TG-100 Era Learning Objectives: Provide an overview and the need for QA usability metrics: Different cultures/practices affecting the effectiveness of methods and metrics. Show examples of quality assurance workflows, Statistical process control, that monitor the treatment planning and delivery process to identify errors. To learn to identify and prioritize risks and QA procedures in radiation oncology. Try to answer the question: Can a quality assurance program aided by quality assurance metrics help minimize errors and ensure safe treatment delivery. Should such metrics be institution specific.

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2016

Crystallization of Sodium Phosphate Dodecahydrate and Re-crystallization to Natrophosphate in Simulated Hanford Nuclear Waste - 16188

The nuclear waste at the Hanford site near Richland, WA, has large concentrations of phosphate in the form of the phosphate ion, sodium phosphate dodecahydrate (Na{sub 3}PO{sub 4}.12H{sub 2}O.(1/4)NaOH) and natrophosphate (Na{sub 7}F(PO{sub 4}){sub 3}.19H{sub 2}O). Sodium phosphate dodecahydrate can form a gel and natrophosphate can crystallize large particles, complicating the processing of slurries of both salts. The gel is regarded as more problematic, so natrophosphate has historically been crystallized to prevent phosphate gelling. This study determined if natrophosphate crystals can grow to large size in short time periods (a few weeks), time periods relevant to short process shutdowns. Solutions of NaOH and NaAl(OH){sub 4} were blended at different ratios with stock solutions containing NaOH, NaF, and Na{sub 3}PO{sub 4} at 50 deg. C. The mixtures were allowed to cool to 22 deg. C, and the crystal growth was monitored by Polarized Light Microscopy (PLM) for 17 days. Four of the six blends investigated gelled rapidly due to Na{sub 3}PO{sub 4}.12H{sub 2}O.(1/4)NaOH precipitation. The gel slowly dissipated over time as the solids recrystallized into natrophosphate. In one case, the natrophosphate reached sizes of greater than 1000 microns in diameter in just 4 days. This rapid gelling and crystallization kinetics is important to engineers trying to manage nuclear wastes high in phosphates. Hanford tank farm engineers are developing sampling plans to support temperature and process control strategies for preventing the formation of solid phosphates. They are also developing methods of suspending large natrophosphate crystals. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2011

Comparison of Routable Control System Security Approaches

This document is an supplement to the 'Secure and Efficient Routable Control Systems.' It addressed security in routable control system communication. The control system environment that monitors and manages the power grid historically has utilized serial communication mechanisms. Leased-line serial communication environments operating at 1200 to 9600 baud rates are common. However, recent trends show that communication media such as fiber, optical carrier 3 (OC-3) speeds, mesh-based high-speed wireless, and the Internet are becoming the media of choice. In addition, a dichotomy has developed between the electrical transmission and distribution environments, with more modern communication infrastructures deployed by transmission utilities. The preceding diagram represents a typical control system. The Communication Links cloud supports all of the communication mechanisms a utility might deploy between the control center and devices in the field. Current methodologies used for security implementations are primarily led by single vendors or standards bodies. However, these entities tend to focus on individual protocols. The result is an environment that contains a mixture of security solutions that may only address some communication protocols at an increasing operational burden for the utility. A single approach is needed that meets operational requirements, is simple to operate, and provides the necessary level of security for all control system communication. The solution should be application independent (e.g., Distributed Network Protocol/Internet Protocol [DNP/IP], International Electrotechnical Commission [IEC] C37.118, Object Linking and Embedding for Process Control [OPC], etc.) and focus on the transport layer. In an ideal setting, a well-designed suite of standards for control system communication will be used for vendor implementation and compliance testing. An expected outcome of this effort is an international standard.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2020

Non-Equilibrium Processes, Stability, Design and Control of Pulsed Plasmas for Materials Processing

The energy and angle of impact of ions, interspersed with fluxes of neutral radicals, on the surface of wafers during plasma materials processing are critical parameters for the fabrication of microelectronic devices, nanostructure materials and biocompatible materials. This sensitivity extends to nearly all applications of plasmas to materials processing and surface modification. Low temperature plasmas for plasma materials processing have traditionally used continuously excited plasmas. However, pulsed plasma processing is an enabling technology for achieving finer resolution of microelectronics fabrication and for producing unique surface properties in a wide range of applications. This research project is addressing fundamental plasma physics issues in materials processing – the control of pulsed plasmas and the means for optimizing plasma produced reactant fluxes.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1995

Designing for Small Volume Assembly of Advanced Electronics Packages

We describe a general methodology to Design for Producibility and Reliability (DFPAR) for very small volume production runs. In cases where the entire volume for fabrication is less than five products, traditional Statistical Process Control (SPC) is inadequate due to reliance on statistics of much larger volumes and the Central Limit Theorem. Data acquisition for process parameter estimation from such a small sample size is difficult; however, it is critical to producing high reliability product.

Central Limit Theorem statistics high reliability ↗

NASA NTRS1993

Welding process modelling and control

The research and analysis performed, and software developed, and hardware/software recommendations made during 1992 in development of the PC-based data acquisition system for support of Welding Process Modeling and Control is reported. A need was identified by the Metals Processing Branch of NASA Marshall Space Flight Center, for a mobile data aquisition and analysis system, customized for welding measurement and calibration. Several hardware configurations were evaluated and a PC-based system was chosen. The Welding Measurement System (WMS) is a dedicated instrument, strictly for the use of data aquisition and analysis. Although the WMS supports many of the functions associated with the process control, it is not the intention for this system to be used for welding process control.

Romine, Peter L.↗

DOE OSTI2018

Steam Reforming Process for Treating Radioactive Waste - 18172

In 2005 the THOR steam reforming fluidized-bed reactor (FBR) technology was selected by the DOE for treatment of sodium-bearing waste (SBW) at the INL. During commissioning a number of equipment reliability and process control challenges were encountered preventing the start of radiological operations. To address these challenges the team adopted a phased systematic mechanistic approach, underpinned by scientific principles and supported by some of the world's leading experts in FBR technology. The Phase 1 effort broadly addressed the entire plant and associated modifications. Phase 2 focused on the most critical issues associated with the denitration and mineralization reformer (DMR) vessel: specifically, mitigation of wall scale (mineral deposits) that formed on the inside of the DMR; mitigation of friable agglomerates (sand-castles) that caused operational instabilities; repair of damaged lower fluidizing gas distributor (ring header), and resolution of auger-grinder (A/G) reliability issues. Basic chemistry and fluidization, as well as operational issues were evaluated using engineering analysis, modeling, bench-scale, pilot scale, and full-scale runs to validate the resolutions. The bench scale testing revealed the need to ensure at least a 5 vol% concentration of CO{sub 2} in the fluidizing gas to minimize undesirable reaction intermediates that could form in less fluidized regions of the bed. Engineering analysis and modeling results pointed to the need to redesign the fluidizing gas distributor to overcome fluidization problems. Chemistry evaluations guided efforts to minimize the deposition of wall-scale. The process modifications were confirmed on the pilot level and are being validated in the full-scale unit (Phase 3). (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2014

Concept, implementation and commissioning of the automation system for the accelerator module test facility AMTF

The European XFEL project launched on June 5, 2007 will require about 103 accelerator modules as a main part of the XFEL linear accelerator. All superconducting components constituting the accelerator module like cavities and magnets have to be tested before the assembly. For the tests of the individual cavities and the complete modules an XFEL Accelerator Module Test Facility (AMTF) has been erected at DESY. The process control system EPICS (Experimental Physics and Industrial Control System) is used to control and operate the cryogenic plant and all its subcomponents. A complementary component of EPICS is the Open Source software suit CSS (Control System Studio). CSS is an integrated engineering, maintenance and operating tool for EPICS. CSS enables local and remote operating and monitoring of the complete system and thus represents the human machine interface. More than 250 PROFIBUS nodes work at the accelerator module test facility. DESY installed an extensive diagnostic and condition monitoring system. With these diagnostic tools it is possible to examine the correct installation and configuration of all PROFIBUS nodes in real time. The condition monitoring system based on FDT/DTM technology shows the state of the PROFIBUS devices at a glance. This information can be used for preventive maintenance which is mandatory for continuous operation of the AMTF facility. The poster will describe all steps form engineering to implementation and commissioning.

43 PARTICLE ACCELERATORS↗

DOE OSTI2015

Modeling precursor diffusion and reaction of atomic layer deposition in porous structures

Atomic layer deposition (ALD) is a technique for depositing thin films of materials with a precise thickness control and uniformity using the self-limitation of the underlying reactions. Usually, it is difficult to predict the result of the ALD process for given external parameters, e.g., the precursor exposure time or the size of the precursor molecules. Therefore, a deeper insight into ALD by modeling the process is needed to improve process control and to achieve more economical coatings. In this paper, a detailed, microscopic approach based on the model developed by Yanguas-Gil and Elam is presented and additionally compared with the experiment. Precursor diffusion and second-order reaction kinetics are combined to identify the influence of the porous substrate's microstructural parameters and the influence of precursor properties on the coating. The thickness of the deposited film is calculated for different depths inside the porous structure in relation to the precursor exposure time, the precursor vapor pressure, and other parameters. Good agreement with experimental results was obtained for ALD zirconiumdioxide (ZrO{sub 2}) films using the precursors tetrakis(ethylmethylamido)zirconium and O{sub 2}. The derivation can be adjusted to describe other features of ALD processes, e.g., precursor and reactive site losses, different growth modes, pore size reduction, and surface diffusion.

36 MATERIALS SCIENCE↗

DOE OSTI2013

Development of ITM Oxygen Technology for Integration in IGCC and Other Advanced Power Generation DECISION POINT 1 UNDER PHASE 3

Air Products and the DOE have partnered over a number of years in the development of ITM Oxygen technology in support of gasification technology. Throughout this process, studies of application of the technology to IGCC and oxy-coal combustion have shown significant reduction in capital and operating costs compared to similar systems using conventional cryogenic air separation. Phase 3, the current phase of the program, focuses on the design, construction and operation of a 30- to 100-TPD pilot facility, the Intermediate Scale Test Unit (ISTU). Execution of this phase to date has resulted in significant advances in a number of areas including ceramic membrane material development, module design and production, ceramic-to-metal seal design, process control strategies, and engineering development of process cycles. Phase 3 will be complete upon successful operation of the ISTU in a series of tests making oxygen from ceramic membrane modules and producing power from a hot gas expander. Phase 3 work has extended beyond the planned schedule due to a delay in delivery of equipment from vendors. Air Products is currently managing the equipment delay by close involvement with the vendor to redesign the problematic equipment and oversee its fabrication. The result of these unforeseen challenges is that the ISTU project completion date has been delayed. Tight cost controls have been implemented both by DOE program management and APCI to meet budget constraints despite increased costs due to budget delays. Total project costs have increased in several areas. Increased costs in the ISTU project include purchased equipment, instruments, construction, and contractor engineering. Increased costs for other tasks include additional work in support of module production by Ceramatec, Inc, and increased Air Products labor for component testing. Air Products plans to complete testing as outlined in the SOPO and successfully complete all project objectives by the end of FY14.

Anderson, Lori↗

NASA NTRS1962

ON THE UNIQUENESS OF TIME-OPTIMAL CONTROL FOR LINEAR PROCESSES

Uniqueness of time-optimal control for linear processes

LINEAR SYSTEM↗

NASA NTRS1992

Intelligent Processing Equipment Projects at DLA

The Defense Logistics Agency is successfully incorporating Intelligent Processing Equipment (IPE) into each of its Manufacturing Technology thrust areas. Several IPE applications are addressed in the manufacturing of two 'soldier support' items: combat rations and military apparel. In combat rations, in-line sensors for food processing are being developed or modified from other industries. In addition, many process controls are being automated to achieve better quality and to gain higher use (soldier) acceptance. IPE applications in military apparel include: in-process quality controls for identification of sewing defects, use of robots in the manufacture of shirt collars, and automated handling of garments for pressing.

Obrien, Donald F.↗

DOE OSTI2018

Renovation of Thermal Vacuum Chambers at Idaho National Laboratory (INL) for Testing of Radioisotope Power Systems (RPS)

The Radioisotope Power Systems (RPS) program at Idaho National Laboratory (INL) fuels and performs environmental testing of RPS in support of National Aeronautics and Space Administration (NASA) missions. Recently the programs’ thermal vacuum chambers, housed within INL’s Space and Security Power Systems Facility (SSPSF), underwent successful renovations to improve functional capabilities and system control in support of customer missions. Thermal vacuum system renovations focused primarily on three core functions. The first focus area was integration of semi-automated Programmable Logic Controllers (PLC) to enhance operational feedback and process control. This included the use of numerically controlled vacuum valves and integration of real time feedback from process pressure transducers. Improvements to the system high vacuum pumping technology was the second priority focus. Legacy diffusion pumps were replaced with turbo-molecular and cryogenic pumps to help mitigate the possibility of back streaming diffusion pump oil onto the surface of the test article or radiative cooling surfaces located within the chambers. The third and final core function involved meeting emergent customer thermal requirements. This led to retro-fitting one of the vacuum chambers with a cryogenically cooled Thermal Conditioning Unit (TCU) and thermal shrouds. The TCU utilizes gaseous nitrogen to heat or cool a cylindrical shroud to maintain a set temperature with a programmable range of -I85 °C to I00 °C. With the successful completion of RPS acceptance testing, the newly renovated thermal vacuum chamber systems are operational and better equipped to support testing of Radioisotope Power Systems for space exploration missions.

42 ENGINEERING↗

DOE OSTI2018

Renovation of Thermal Vacuum Chambers at Idaho National Laboratory for Testing of Radioisotope Power Systems

The Radioisotope Power Systems (RPS) program at Idaho National Laboratory (INL) fuels and performs environmental testing of RPS in support of National Aeronautics and Space Administration (NASA) missions. Recently the programs’ thermal vacuum chambers, housed within INL’s Space and Security Power Systems Facility (SSPSF), underwent successful renovations to improve functional capabilities and system control in support of customer missions. Thermal vacuum system renovations focused primarily on three core functions. The first focus area was integration of semi-automated Programmable Logic Controllers (PLC) to enhance operational feedback and process control. This included the use of numerically controlled vacuum valves and integration of real time feedback from process pressure transducers. Improvements to the system high vacuum pumping technology was the second priority focus. Legacy diffusion pumps were replaced with turbo-molecular and cryogenic pumps to help mitigate the possibility of back streaming diffusion pump oil onto the surface of the test article or radiative cooling surfaces located within the chambers. The third and final core function involved meeting emergent customer thermal requirements. This led to retro-fitting one of the vacuum chambers with a cryogenically cooled Thermal Conditioning Unit (TCU) and thermal shrouds. The TCU utilizes gaseous nitrogen to heat or cool a cylindrical shroud to maintain a set temperature with a programmable range of -I85 °C to I00 °C. With the successful completion of RPS acceptance testing, the newly renovated thermal vacuum chamber systems are operational and better equipped to support testing of Radioisotope Power Systems for space exploration missions.

42 ENGINEERING↗

DOE OSTI2018

Renovation of Thermal Vacuum Chambers at Idaho National Laboratory (INL) for Testing of Radioisotope Power Systems (RPS)

The Radioisotope Power Systems (RPS) program at Idaho National Laboratory (INL) fuels and performs environmental testing of RPS in support of National Aeronautics and Space Administration (NASA) missions. Recently the programs’ thermal vacuum chambers, housed within INL’s Space and Security Power Systems Facility (SSPSF), underwent successful renovations to improve functional capabilities and system control in support of customer missions. Thermal vacuum system renovations focused primarily on three core functions. The first focus area was integration of semi-automated Programmable Logic Controllers (PLC) to enhance operational feedback and process control. This included the use of numerically controlled vacuum valves and integration of real time feedback from process pressure transducers. Improvements to the system high vacuum pumping technology was the second priority focus. Legacy diffusion pumps were replaced with turbo-molecular and cryogenic pumps to help mitigate the possibility of back streaming diffusion pump oil onto the surface of the test article or radiative cooling surfaces located within the chambers. The third and final core function involved meeting emergent customer thermal requirements. This led to retro-fitting one of the vacuum chambers with a cryogenically cooled Thermal Conditioning Unit (TCU) and thermal shrouds. The TCU utilizes gaseous nitrogen to heat or cool a cylindrical shroud to maintain a set temperature with a programmable range of -I85 °C to I00 °C. With the successful completion of RPS acceptance testing, the newly renovated thermal vacuum chamber systems are operational and better equipped to support testing of Radioisotope Power Systems for space exploration missions.

42 ENGINEERING↗