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DOE OSTI2022

Advanced Airfoil Cooling Schemes to Increase Efficiency in Gas Turbines for Combined Heat and Power Applications

This report describes a three-year interdisciplinary effort funded by the U.S. Department of Energy’s (DOE) Energy Efficiency and Renewable Energy/Advanced Manufacturing Office (EERE/AMO) to promote market penetration of combined heat and power (CHP) technologies. Prior studies have shown the technical potential for CHP in the United States is much larger than the current deployment of CHP systems. A large portion of the technical potential CHP market aligns with small (<20 MWe) gas turbines. CHP systems are an attractive alternative to reduce greenhouse gas (GHG) emissions. For example, CHP systems can reduce GHG emissions by 30–40% relative to a conventional boiler and power configuration. These GHG emission reductions are “avoided emissions” which means no CO 2 separation or sequestration is required. This report describes an effort to use additive manufacturing (AM) technologies and advanced airfoil cooling designs to increase the turbine inlet temperature by 100 °C for small gas turbines typically used in CHP systems. At the beginning of this effort, baseline performance data for small gas turbines was not available, and the potential benefits of cooling system improvements were not quantified in the available literature.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Updates to Nek5000: RANS wall functions, NRC support, and documentation

As a key part of the U.S. Department of Energy’s Nuclear Energy Advanced Modeling and Simulation program (NEAMS), the next generation of tools for nuclear reactor design are being developed. A primary metric for success of this program is the adoption of those tools by industry stakeholders. To help meet this metric for Nek5000, development efforts this year have focused on the expansion of the available Reynolds-averaged Navier-Stokes (RANS) turbulence models to include wall function models, continued support of the U.S. Nuclear Regulatory Commission in simulating a hydrogen mitigation benchmark experiment, and expansion of the Nek5000 documentation to enhance the code’s usability. The implementation of wall functions is intended to significantly decrease time to-solution for a wide range of problems and it has been identified as an important feature by stakeholders across the nuclear community. The initial implementation of standard and pressure corrected wall functions has been tested in Nek5000 on the classical problems of channel flow and a backward facing step. It has also been tested on a 2D molten salt fast reactor core and a T-junction. The recommended formulation of choosing y + = 30 as a boundary value combined with a Neumann-Neumann formulation of the boundary condition for k and τ produces the most consistent results compared to a wall resolved approach. The collaboration with the NRC is a continuing exercise that has been ongoing for multiple years. This year we have concluded investigations into appropriate inlet conditions, showing that fully developed turbulent conditions are adequate for the full PANDA domain. We have also concluded simulations for an unobstructed jet and are now refocusing to the original obstructed jet case. The expansion of the code documentation has also been an ongoing effort over the past few years to address feedback from the various stakeholders. The documentation now more fully covers many of the available features and closes identified SQA gaps. Finally we report on three training sessions that were offered over the past year in an effort to expand the Nek5000 user base.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

1D Modeling for the Development of a Digital Twin for Hydropower Systems with Applications for a Testing Rig

Modeling and simulation constitute two important parts in constructing a sensible digital twin to mimic the dynamics of hydropower systems. Because of the physical nature of a hydropower system, the basic modeling should cover the water flow systems from the reservoir to the penstock (inlet water pipes), penstock to hydro turbine, and hydro turbine to generator and from the linkage of the hydropower systems to the grid. This report describes initial attempts to model these dynamic components, including the formulation of the linearized state space model for hydro turbine systems using the well-known six-coefficients linearization method and the formulation of the voltage and power dynamical models of a synchronous generator. To validate the accuracy of the proposed model, data collected from Norwegian University of Science and Technology were used to obtain relevant parameters for the model, and the desired simulation results were obtained. Additionally, neural network modeling and learning were also developed and applied to model the generation torque and water flow rate subsystems to demonstrate a potential learning scheme, which can be used in the development of a digital twin.

13 HYDRO ENERGY↗

DOE OSTI2022

Integrated Transpiration and Lattice Cooling Systems developed by Additive Manufacturing with Oxide-Dispersion-Strengthened (ODS) Alloys (Final Report)

The primary goal of this research was to develop an innovative approach to provide a significantly improved level of thermal protection for hot-section components, such as turbine airfoils, in modern and future gas turbines. Current and future designs for “air breathing” turbine systems are targeting turbine inlet temperatures of 1700°C or higher, which is well beyond the substrate melting temperature, and a combined cycle energy efficiency of 65%. Meanwhile, targeted cycle efficiency calls for a reduction of the amount of coolant air significantly below the current level. Hence the development of novel internal airfoil designs that provide a satisfactory level of component durability with affordable coolant management is critical to the further advances of today’s turbine technology. This project was a response to this grand challenge with the research efforts primarily focused on the development of integrating transpiration cooling with lattice enhanced internal cooling. The research on these advanced cooling technologies was accompanied with development of anti-oxidation material in the form of oxide dispersion strengthened (ODS) alloy which also possessed enhanced high temperature strength. A novel approach of fabricating the ODS alloy as powder with high compatibility with state-of-the-art additive manufacturing (AM) process was also developed.

03 NATURAL GAS↗

DOE OSTI2020

Advanced Steam-Electric Power Cycle for Advanced Reactor Concepts

This report presents improvements made to RELAP-7 for modeling Rankine power cycles, which are used on the secondary side of some advanced reactor concepts. For example, for a High-Temperature gas-cooled Reactor Pebble bed Module (HTR-PM), in the primary loop, helium transfers heat from the fuel to a steam generator, and on the secondary side, dry steam from the steam generator applies work to a turbine, which is converted into electrical power by a generator. After passing through the turbine, the steam passes through a condenser and pumped to the steam generator inlet, completing a Rankine cycle on the secondary side. This HTR-PM concept is used as an example to demonstrate a steam-electric power cycle capability in RELAP-7. This power cycle requires a number of different physical components, including a pump, compressor, turbine, steam generator, and condenser. The steam generator is modeled using a heat exchange between primary and secondary loops, and the condenser is modeled using a cooling source term. Recent efforts demonstrated preliminary models for the turbomachinery components (pump/compressor and turbine), but more physical models were required. Furthermore, several improvements were made for the robustness of mixed single-phase/two-phase flow present in a Rankine cycle.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

SAS4A/SASSYS-1 Validation with EBR-II Tests Performed During the SHRT Testing Program (Rev. 2)

The EBR-II sodium-cooled fast reactor supported a wide range of fast reactor research activities. The final fifteen years of operations at EBR-II were used for experiments and tests to demonstrate the importance of passive safety in liquid metal reactors and the capability of such systems to provide strong passive responses during off-normal conditions. The Shutdown Heat Removal Test program at EBR-II provided test data supporting the validation of computer codes for design, licensing, and operation of LMRs, among other objectives. The program included nearly sixty tests, most of which were protected and unprotected loss of flow and loss of heat sink tests run at various initial powers and flow rates. This report documents the results of modeling and simulation of tests from the Shutdown Heat Removal Test program to support validation of Argonne’s SAS4A/SASSYS-1 fast reactor safety analysis code. SHRT-17 and SHRT-6 were protected loss of flow tests where a loss of electrical power to all sodium coolant pumps was simulated to demonstrate the effectiveness of natural circulation cooling characteristics. SHRT-45R, SHRT-39, and SHRT-43R were unprotected loss of flow tests where the control rod scram function of the plant protection system was disabled to demonstrate the effectiveness of EBR-II’s passive reactivity feedbacks. BOP-301 and BOP-302R were unprotected loss of heat sink tests that demonstrated how reactivity feedback effects driven by changes to the core inlet temperature can shut down the fission process. PICT-5/6 demonstrated how core power could be increased and decreased via changes in the intermediate sodium and feedwater flow rates. This validation activity leverages modeling and simulation efforts that originated under an International Atomic Energy Agency Coordinated Research Project for benchmark analysis of the EBR-II Shutdown Heat Removal Tests. The SAS4A/SASSYS-1 models originally developed for the CRP have been modernized to utilize new code features and modeling practices. Differences between the predicted and measured test data were explored and the causes of these differences were identified as being due to modeling approximations, uncertainty in transient component behavior, and instrumentation uncertainties. Overall, it was concluded that for all tests simulated there was good agreement between the flow, power, and temperature predictions and the measured data.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Operation, maintenance, and installation instructions for HLW thermal catalytic oxidizer/reducer (TCO)

The HLW TCO Units are a combination of four rectangular vessels; the Recuperative Heat Exchanger, Electric Heater, Selective Catalytic Oxidizer (SCO), and the Selective Catalytic Reducer (SCR). Each housing is simply a closed rectangular box with formed angle stiffeners welded to the outside perimeter. The housings are connected with process piping and sit on a skid. There is an external frame to support all major process piping and the Electric Heater. The process piping consists of a 14" inlet which enters the heat exchanger. Then the off-gas flows through 18" cross over piping which leads to the heater. Once the off-gas is heated, another section of 18" process piping leads the off-gas through the SCO and SCR. The off-gas then flows through the heat exchanger before exiting through 16" process piping which leads to the customer's piping. The other equipment associated with the HLW TCO is the Ammonia Dilution Skid. The dilution skid controls the ammonia injection into the off-gas. The dilution skid supports two process lines, a 2" line and a 1" line which carries process air and anhydrous ammonia respectively. Ammonia injection into the off-gas is required prior to entering the SCR to ensure the NOx reduction occurs through the SCR catalyst bank.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Terrain-Influenced Winds and Fire-Fire Interactions in Wildland Fire Simulations [Dissertation]

Ensemble-based approaches to prescribed fire planning cannot be supported by computational fluid dynamics based models like FIRETEC and the Wildland-Urban Interface Fire Dynamics Simulator (WFDS) because they are too computationally expensive and cannot leverage large eddy simulation approaches like CAWFE and WRF-SFIRE because they have too coarse of resolution. QUIC-Fire was developed to fill this gap but it cannot currently address complex terrain, that is typical for instance in the Western United States. This dissertation describes a variety of improvements made to QUIC-Fire and its various incorporated algorithms in an effort to make it a viable tool in simulating wildland and prescribed fires on terrain. The modifications made to QUIC-Fire are described in three chapters. The first chapter describes the extension of the diagnostic wind model QUIC-URB, the wind engine of QUIC-Fire, to a terrain-following coordinate system. The terraininfluenced winds it generates are analyzed and compared. In particular, this chapter presents the mathematical derivation of the wind solver leading to a linear system of equations that are solved through the successive over-relaxation method. The model is validated against a standard test used in previous works (the Askervein Hill) and against a new dataset from measurements in the Socorro Mountains, New Mexico. The terrain-following implementation captures the correct phenomenology for the isolated Askervein Hill, with a wind speed up at the top of the hill. The model agrees well with measurements on the upwind side of the peak, but overestimates speed-up on the downwind side of the hill. This is due to the inability of the model to generate flow separation and wake-eddy dynamics. On a common laptop, the divergence-free wind field is obtained in 6 s, making the solver appealing for coupled fire-atmosphere simulations. The Socorro Mountain is highly complex, with many cliff faces, peaks, and valleys. Although the model captures the magnitude and direction of inlet and outlet areas of the domain, it performs rather poorly in the valley region and in the regions near the steep cliffs. Hence, the model shows good agreement with data in areas of open sloped terrain but lacks in areas where flow separation and thermally driven effects may be present (neither effect is addressed in this work). In the second chapter the implementation of the terrain-following version of QUIC-URB into QUIC-Fire, and the necessary changes needed to include terrain are described. No changes to the underlying fire spread algorithm are made other than what is required to correctly account for the inclusion of terrain. Previously published FIRETEC results that use five different topographies that share the same centerline profile are compared to simulation results from the modified QUIC-Fire that use the same topographies and fuels. QUIC-Fire results show overall similar behaviors in terms of how the topographies affect fire shapes and trends in spread rates. Due to the terrain-following version of QUIC-URB being unable to generate flow separations at the crest of hills, fire spread rates in these regions across all topographies are over-predicted when compared to FIRETEC. Lateral fire growth shows similar trends with FIRETEC between topographies but does not capture the increase in spread due to a diagonal interface between grassland and forested fuel region of the domain. These results suggest that there are three algorithms within QUIC-Fire that could use improvement: how flame tilt angle is accounted for, the incorporation of non-local drag effects, and the inclusion of the wake-eddy parameterizations that are used in QUIC-URB. Lastly, the third chapter describes a modification to the initial guess used for the calculation of the QUIC-URB mass-conserved wind solution during fire simulations. The modification is aimed at improving fire-fire interactions in QUIC-Fire simulations. The modification consists of using the solution from the previous timestep as the starting point for the calculation of the solution for the next timestep. Fire-fire interactions is greatly improved by the change but a new source of error is introduced. Due to how plumes are modelled in QUIC-Fire the new solution contains errors where gaps in the plume structure are present. However, these errors are mostly limited to the upper atmosphere, where they do not affect fire behavior at the surface, and their magnitude isn’t significant enough to discount the amount of new fire phenomenology now captured in QUIC-Fire with the change.

58 GEOSCIENCES↗

DOE OSTI2022

CFD Simulations to Support Pronghorn Modeling of a Molten Salt Fast Reactor

To assist with the deployment of next generation molten salt reactors (MSRs), the DOE NEAMS program is developing advanced simulation capabilities. As part of this work, the high-fidelity CFD tool, Nek5000 was used to inform model development for the engineering scale tool, Pronghorn. The particular case chosen was the EVOL molten salt fast reactor concept. This concept uses an open core design, which is well known to be sensitive to the particular geometry and can have complex flow behavior that varies across a range of conditions. This makes it an idea candidate for demonstration of the Hi2Lo concept of using higher fidelity models to benchmark lower fidelity models. Simulations of the EVOL design were performed using both LES (high-fidelity) and RANS (moderate-fidelity) in Nek5000. The LES results indicated discrepancies in 2-D axisymmetric RANS, indicating that the core is better modeled in RANS with a 3-D wedge representation of a portion of the core, which can accurately account for the effect of the inlet channels. Finally, results from the 3-D RANS were used to modify an existing turbulence model in Pronghorn. Improvement in the calibrated Pronghorn model was demonstrated. Future work is suggested to focus on expanding the LES calculation to provide a more direct point of comparison for both the RANS and Pronghorn models as well as incorporating more of the relevant MSR physics (such as delayed neutron precursor tracking) into the model.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Assessment of Sodium Thermal Stratification Models Utilizing the TSTF Benchmark

As a result of certain transient scenarios, a thermally stratified layer of liquid sodium can develop in the bulk coolant volumes of a sodium-cooled fast reactor (SFR). In addition to the effects a stratification layer has on the temperature of the heat transport system, a stratification layer can also influence the transition to and establishment of natural circulation flow, which plays an important role in passive cooling and the inherent safety of a pool-type SFR. Therefore, the ability to accurately capture thermal stratification phenomena is important when demonstrating the safety basis of a pool-type SFR during transient sequences. The present work assesses various computational models with different fidelities in their ability to predict thermal stratification in the upper plenum of an SFR. Each computational model will be assessed using the data generated at the Thermal Stratification Test Facility (TSTF) located at the University of Wisconsin-Madison. Using measured flow rate and inlet temperature data, the measured temperature distributions of the tests are compared to the predictions of the lumped volume-based models in SAS4A/SASSYS-1, a 1D-based model in SAM, and a 3-D computational fluid dynamics (CFD) model using STAR-CCM+. The relative performance of the various computational methods is assessed with respect to key metrics such as bulk coolant temperature distribution and plenum exit temperature. A total of eight tests are analyzed, covering different combinations of flow rates (3 and 10 GPM) and upper internal structure (UIS) configurations (none, solid, porous, and open) The perfect mixing model of SAS4A/SASSYS-1 provides the highest accuracy when the flow rate is high and there is no UIS in the test vessel, as high flow rate injection promotes thermal mixing of the sodium in the test vessel. For most of the analyzed tests, the stratified volume model of SAS4A/SASSYS-1 is able to predict the delay in the outlet temperature drop and temperature distribution in the test vessel by a small number of layers to represent thermal stratification. However, the stratified volume model can only simulate a maximum of three temperature layers within a volume and when a layer approaches the elevation of the outlet, the predicted outlet temperature can demonstrate rapid, non-physical changes. The 1-D axial mixing model of SAM provides results that agree reasonably well with the measured data in the prediction of the temporal evolution of the outlet temperature with the exception of the case with a high flow rate and no UIS. The SAM 1-D model has a similar level of accuracy to CFD results when it comes to predicting the outlet temperature. CFD shows overall good agreement in predicting the temperature distribution in the test vessel and outlet temperature. As CFD can model the test vessel geometry in detail, it performs well in the cases of complex geometries such as tests that included a UIS and internal flow through the UIS resulting in active mixing of the coolant in the test vessel. Each of the models discussed in the present work has the potential to be useful during the various stages of reactor design, analysis, and licensing. The lumped-volume approach can be applied for fast turnaround safety calculations to obtain overall reactor behavior during transients. The 1-D models provide improved accuracy when stratification is expected for a relatively low increase in the computational cost. The CFD model can be utilized for confirmatory analysis of the 1-D model, when experimental measurements are not available.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

DPE Techno-Economic Analyses

This National Energy Technology Laboratory (NETL) report presents the results of an extensive set of techno-economic analyses for several open-cycle coal fuel oxy-fired direct power extraction (DPE) concepts. These power cycles make use of a conducting plasma accelerated through a magnetic field to generate direct current directly without the need for moving parts. Similar to gas turbines, the efficiency of the power cycle increases with increasing working fluid temperature and typically, plasma temperatures are much higher than the inlet temperature of even the most advanced gas turbine available today, affording the opportunity for very high cycle efficiencies. Most of the study uses high-fidelity models to assess a coal-fueled oxy-combustion DPE system with an AUSC steam bottoming cycle. Two baseline configurations were explored, one with relatively conservative operating point parameters and another with relatively aggressive operating point parameters. Additional analysis on the high-fidelity models as well as reduced order models were performed to analyze the cost and performance potential more thoroughly for the baseline systems and to compare their performance to two alternate open-cycle DPE systems.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2023

Scaling hyporheic nitrogen cycling in large river alluvial aquifers

Research Element 1: Denitrification is a difficult flux to measure when fluxes are low and when the ecosystem is difficult to sample. These attributes describe Nyack floodplain, a large gravel-bedded aquifer adjacent to the Middle Fork Flathead River. Given that denitrification is simply respiration with nitrate as a terminal electron acceptor, we reasoned that N 2 production should negatively covary with oxygen respiration so long that oxygen is available. We sampled 16 wells 8 times throughout a year and analyzed these water samples on a membrane-inlet mass spectrometer for N 2 :Ar and O 2 . We fit multilevel models to N 2 :Ar as a function of dissolved oxygen. Within wells, there was no relationship between O 2 and N 2 :Ar. Among wells N 2 :Ar increased as O 2 declined. Based on the slope of this relationship, ~ -0.07, and estimated oxygen respiration in Nyack derived from prior studies, a possible range for denitrification is 0-8 mmol m -2 d -1 corresponding to a turnover rate for nitrate of 0-0.2/d. This estimated turnover rate is in the lower 20% of rates measured in the LINX 2 study, yet shows that even in a low nitrate (0.005 mmol/L) aquifer denitrification can be a substantial sink for dissolved N. Research Element 3 and 4: We developed a new theoretical approach to describe the relationship between water inflow, water outflow, and water age in porous media control volumes under dynamic flow conditions. Our approach had three distinct steps. First we described the application of well-established equations borrowed from Chemical Engineering to describe water age distributions in the hyporheic zone under steady state conditions. We published the associated results in the scientific journal PLOS ONE. Second, we developed a new theory ("flow spans") to describe how predicted steady-state water age distributions will respond to time varying imbalances in hyporheic discharge and recharge. Finally, we developed a proof-of-concept simulation model based on the new theory and used the model to examine the effects of flow regulation on a simulated river with characteristics representative of western U.S. montane rivers with expansive hyporheic zones.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

FY23 Progress on Computational Modeling of the Water-Based NSTF

This report summarizes the system-level modeling effort by Argonne National Laboratory (Argonne) of the Natural convection Shutdown heat removal Test Facility (NSTF) in FY23. As a continuation of the modeling effort from FY22, this year’s work focuses on improving the RELAP5-3D model developed previously for two-phase flow simulations. The RELAP5-3D model is updated to more accurately capture the heat loss experienced by the facility. The updated model is compared against experimental data for benchmarking purposes of the RELAP5-3D input model. By correctly accounting for heat loss, the updated RELAP5-3D model can now predict the two-phase baseline case more accurately. The onset and the duration of instability are captured well by the model. Furthermore, analyses are performed to better understand the instability mechanism experienced by the flow where the expansion of the boiling boundary in the chimney is studied in details and the fundamental frequencies of the oscillations are obtained. The updated RELAP5-3D model is further compared against four fault conditions, namely the reduction of riser header inlet flow area, depletion of system inventory, blocked riser channels, and static boiling scenario. For each fault condition, minor modifications and tuning are performed to improve the predictions of the model. The purpose of the analyses is to investigate the capability of RELAP5-3D in predicting complex two-phase flows in possible accident scenarios in actual Reactor Cavity Cooling System (RCCS). Overall, the model is able to capture the behaviors and trends of these fault conditions relatively well. Some discrepancies remain between the experimental data and the predictions, many of which are likely due to the differences in the predicted and experimental vapor generation rate. Future work will focus on the continued development of the current RELAP5-3D input model of the NSTF to both improve the accuracy of the model’s predictive capability and continue supporting the experimental program needs. The mutually beneficial relationship between analysis and experimental efforts has become integral to the parent NSTF program, and the greater objective to fully understand and accurately predict the heat removal performance of a full scale RCCS concept.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

The Vela Hotel Program: The AEC's Space-Based Nuclear Detection and Treaty Verification Program [Slides]

Early Interest in "Detection": "I would suggest that the best way to get reliable information in a short time would be to send from the States a man qualified to do the testing of the samples on the spot. This man should be officially a representative of the State Department, and his detecting devices, such as small portable Geiger Counters, could then go into Switzerland in the diplomatic pouch via air from Southern Italy. This man could then contact, through the Embassy, suitable people who could collect the water samples without arousing too much curiosity. A fishing trip in a boat would probably give the best disguise, as the fisherman could carry a water bottle in his lunch basket, and fill it after drinking the original contents. The water should be collected from the center of the river, to get the swiftest flowing water, so that the holdup could be minimized. In the lake, the water should be collected as near to the suspected site as possible, or as near to each of the inlet rivers as can be done. Speed in getting from the collection point to the counting room is of great importance, as you are, no doubt, aware." - Luis Alvarez to Major Furman, May 1944.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

Conversion of METL Diagnostic Flowmeters to Permanent Magnet Based Electromagnetic Flowmeters

The Mechanisms Engineering Test Loop (METL) uses three flowmeters to monitor sodium circulation through the main loop, the Cold Trap leg, and the Plugging Meter leg. When constructed, the Cold Trap flowmeter (CTFM) and Plugging Meter flowmeter (PMFM) were equipped with permanent magnets and Hall Sensors. By October of 2019, during normal operations, both the CTFM and PMFM failed, producing either erroneous or zero signals. Repairs to the flowmeters were attempted in January of 2020 but failed to resolve the issues. Therefore, starting in March of 2021, a plan was developed to convert the installed flowmeters to more robust permanent magnet based electromagnetic flowmeters (EMFMs). The Cold Trap EMFM (CT EMFM) and Plugging Meter EMFM (PM EMFM) were fully installed by August of 2021. Initial testing and commissioning were completed in November of 2021. Finally, the first calibration runs were finished in March of 2022. This report discusses the design, conversion, and calibration of the as-built CTFM and PMFM to robust permanent magnet based EMFMs. During the design phase, theoretical models were used to estimate the signal output and required magnet sizes. Then, the CTFM and PMFM were disassembled and converted to EMFMs. After commissioning, the CT EMFM and PM EMFM were calibrated using a ‘Time Transfer Procedure’ carried out with METL Expansion Vessels and Test Vessel Two. The accuracy of the calibration was estimated through an uncertainty analysis. Finally, the report describes some lessons learned for future flowmeter conversions and follow-up work. In total, both METL EMFM’s met the desired performance targets. Testing data showed that the METL EMFMs provide a output signal of roughly 2 mV at 1 GPM and 250 °C. During calibration, flowrates between 0.7 GPM and 2.4 GPM were achieved. In this flow range, calibration coefficients of 0.485 and 0.935 were measured as with errors ranging from 15-5% and 16-5% for the CT EMFM and PM EMFM, respectively. Above 1.5 GPM, the error was assumed to be about 5% for both METL EMFMs. Several points will be considered for future follow-up work on the METL EMFM’s. First, the signal noise issues in the PM EMFM will be addressed. It is likely the source of the noise is due to some stray EMF from a heater. Secondly, the NdFeB magnets will be replaced with a grade that has a Curie temperature above 80 °C. For example, a few grades of NeFeB magnets have Curie temperatures which exceed 150 °C and some SmCo magnets have Curie temperatures as high as 500 °C. Third, more calibration runs will be completed in the range of 0.5-2.5 GPM. This will further improve the accuracy of the calibration coefficient. Fourth, calibration runs will be completed up to 5 GPM. This requires a larger pressure relief valve to be installed on the Expansion Vessel and Test Vessel 2, as well as a revised calibration procedure. Lastly, calibration runs will be completed to account for cold spots in the system, which reduced the inlet temperature of the METL EMFMs. Overall, these points will improve the calibration coefficients derived in this work and also improve the performance of the METL EMFMs.

42 ENGINEERING↗

DOE OSTI2023

Coupling Thermal-Hydraulics with Reactor Pressure Vessel Fracture Models

Because of the importance of maintaining the integrity of the reactor pressure vessel (RPV) in light-water reactors, significant effort has been devoted over the last several decades to understand the potential failure mechanisms, characterize how material properties evolve due to environmental conditions, and develop tools to assess the probability of fracture in aged RPVs during potential transient events. One important aspect of this problem that has not yet been fully addressed is the effects of nonuniform cooling on the RPV inner wall due to the way low-temperature water injected into the primary coolant system is distributed within the RPV during potential loss-of-coolant accident transients. Colder temperatures are expected in the regions near the inlets, causing a “cold-plume” effect. Rapid cooling of the RPV wall increases the likelihood of fracture initiation, and localized cooling due to cold-plume effects could potentially exacerbate this problem. The Grizzly code can perform a three-dimensional simulation of the RPV thermomechanical response as well as the probabilistic assessment of fracture for a population of pre-existing flaws, which is necessary to account for spatial variations in coolant temperature. This report documents a first effort to couple Grizzly RPV fracture models with computational fluid dynamics models performed using the Cardinal code, which allows for a realistic representation of the temperature distribution. This report demonstrates this coupling approach on two test cases: a simplified proof-of-concept scenario and a realistic small-break loss-of-coolant accident scenario. In both cases, the effects of the spatially varying temperature are evident; although, because the small-break loss-of-coolant accident scenario was far from challenging the RPV’s margins, it is still inconclusive how important cold-plume effects are in realistic accident scenarios. However, this effort represents an important step toward performing realistic analyses to determine to what extent spatially nonuniform cooling might affect RPV integrity under more aggressive accident scenarios.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Experimental and Computational Studies of Stress Corrosion Cracking of Alloys 308/309 and 82/182 Weldments in Corrosive and Radiation Environment

The goal of the project was to determine factors that influence SCC and IASCC in weldments found in LWR nuclear power plants. We focused on a SA508-304L SS weldment fabricated by EPRI using gas tungsten arc welding and used an aggressive BWR normal water chemistry (NWC) immersion environment. This weldment used 309L butter and 308L groove filler material. The microstructure of the 309L butter was non-uniform, exhibiting a 20–30μm thick martensitic layer closest to the SA508 interface, a 1–4 mm thick single γ austenite phase dilution zone, and a γ–δ duplex region extending to the 308L groove filler. The 308L groove filler had an entirely γ–δ duplex microstructure. Two approximately 1-inch thick 304L and SA508 plates approximately 12 by 6 square inches were joined using standard nuclear grade welding techniques. This included a post weld heat treatment of the 309L butter after application, a 0.32 cm fit-up root opening, and 57 bead lines of 308L groove filler applied in 18 layers. A 60 degree weld bevel angle was used and the 309L butter was 1.5 cm thick. Displacement cascade damage was induced using proton irradiation at the Michigan Ion Beam Laboratory. The incident proton energy was 2 MeV, the sample temperature was 360 ºC, and the calculated dpa value at 10 μm (60% of the Bragg peak depth of ~18 μm) was 5 dpa using the quick Kinchin-Pease model. Proton irradiation to this damage level required approximately 125 hours of beam time. Two types of samples were irradiated, tensile specimens and TEM bars. Samples were selected from all regions of the weldment, including the SA508-309L butter interface, the 309L-308L interface, and 308L-304L interface. The stainless steel alloys (304L, 308L, and 309L) within the heat affected zone are characterized by a duplex skeletal morphology of δ-ferrite and γ-austenite resulting from the recrystallization associated with weld fabrication. Approximately 7 to 8 mm of length along the specimen was irradiated. The gauge volume surfaces were mechanically polished and then electro-polished to remove mechanical damage from the mechanical polishing step prior to irradiation. Immersion tests were performed in a recirculating autoclave under BWR NWC conditions (2000 ppb wt. dissolved oxygen, neutral pH, 288 ºC, 10 MPa, and inlet water conductivity <100 nS/cm) to accelerate corrosion. Constant strain rate tests were performed either to failure or to approximately 5% strain. Strain rates of 10 -7 to 10 -6 mm/mm/s were used and typical immersion testing required four to six weeks to achieve failure or strains near 5%. Analysis primarily used advanced electron microscopy techniques of FIB lift out specimens.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

RANS Simulation of Variable Density Turbulent Round Jets with Coflow using xRAGE Hydrodynamic Code and BHR Turbulence Models

This work for the fiscal year 2023 (FY23) is a continuation of previous efforts to evaluate the BHR turbulence models for their ability to accurately simulate variable density turbulent round jets with coflow. As before, RANS simulations are carried out using the xRAGE hydrodynamic code. The following are some of the previous findings. Israel showed that i) the symmetry boundary conditions for the BHR models in axisymmetric simulations were in error, ii) three grids of different resolutions did not lead to converging solutions, and iii) BHR 3.1 simulation exhibited instabilities and did not reach a steady state. Saenz and Rauenzahn derived and implemented into xRAGE the correct BHR boundary conditions at the symmetry axis. Cline conducted sensitivity studies with various parameters including the BHR models (versions 2, 3.1 and 4), gravity, material pressure, specific heat, initial turbulent kinetic energy and initial turbulent length scale, and found that the largest factor impacting on simulation results was the BHR model version, followed by the initial turbulent length scale. In addition, freeze boundary conditions at the exit and the side wall of the computational domain were used to remove anomalous flow behavior. Cline adjusted the inlet jet velocity, initial turbulent kinetic energy and initial turbulent length scale to obtain the best reasonable match with the experimental data of Charonko and Prestridge. It was found that the BHR 2 and 3.1 models performed in a similar manner, but the BHR 2 model produced much lower levels of density-specific-volume covariance and turbulent kinetic energy. The main focus for the FY23 is to study the effects of computational parameters related to the boundary conditions, mesh, domain size and timestep size. The reasoning behind this is that, unless simulation results can be shown to be reasonably independent from the aforementioned computational parameters, it would be difficult to attribute any discrepancies between simulation and experimental results to turbulence models. This important aspect has largely been overlooked in the previous years, and therefore will be studied comprehensively here. Additionally, effects of varying the initial turbulent length scale will be examined because it was previously identified as a major factor affecting the flow fields.

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