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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 631 records · Page 35

Motel solar hot-water installation--Atlanta, Georgia

Analysis of hardness of local water, average insolation for site, and daily hot water requirements insures suitability of solar-energy system design. Report describes two units which are designed to supply 81 percent of motel's annual hot water demand based on hypothetical 85 percent occupancy. Report includes drawings, operating and maintenance instructions, and test results for 1 day of operation.

Source record↗

NASA Global Hawk: A Unique Capability for the Pursuit of Earth Science

For more than 2 years, the NASA Dryden Flight Research Center has been preparing for the receipt of two Advanced Concept Technology Demonstration Global Hawk air vehicles from the United States Air Force. NASA Dryden intends to establish a Global Hawk Project Office, which will be responsible for developing the infrastructure required to operate this unmanned aerial system and establishing a trained maintenance and operations team. The first flight of a NASA Global Hawk air vehicle is expected to occur in 2008. The NASA Global Hawk system can be used by a variety of customers, including U.S. Government agencies, civilian organizations, universities, and state governments. Initially, the main focus of the research activities is expected to be Earth science related. A combination of the vehicle s range, endurance, altitude, payload power, payload volume, and payload weight capabilities separates the Global Hawk unmanned aerial system from all other platforms available to the science community. This report describes the NASA Global Hawk system and current plans for the NASA air vehicle concept of operations, and provides examples of potential missions with an emphasis on science missions.

Naftel, J. Chris↗

NASA Global Hawk: A Unique Capability for the Pursuit of Earth Science

For more than 2 years, the NASA Dryden Flight Research Center has been preparing for the receipt of two Advanced Concept Technology Demonstration Global Hawk air vehicles from the United States Air Force. NASA Dryden intends to establish a Global Hawk Project Office, which will be responsible for developing the infrastructure required to operate this unmanned aerial system and establishing a trained maintenance and operations team. The first flight of a NASA Global Hawk air vehicle is expected to occur in 2008. The NASA Global Hawk system can be used by a variety of customers, including U.S. Government agencies, civilian organizations, universities, and state governments. A combination of the vehicle s range, endurance, altitude, payload power, payload volume, and payload weight capabilities separates the Global Hawk unmanned aerial system from all other platforms available to the science community.

Naftel, J. Chris↗

High-Temperature Microwave Acoustic Vibration Sensor

High-temperature vibration sensors are desired in a number of contemporary harsh-environment applications, namely: power plants, metallurgy, aerospace, and defense. The detection of vibrations in these applications is important for providing condition-based maintenance (CBM) for electronic, mechanical, and structural systems, thus reducing operating and maintenance costs, improving industry efficiency, and increasing safety. Microwave surface acoustic wave resonator (MSAWR) sensors have the potential of being used as high-temperature vibration sensors due to their proven harsh-environment operation, small size, battery-free, and wireless capability. This paper explores the MSAWR as a vibration sensor mounted and tested up to 500°C. A 193MHz langasite-based MSAWR sensor was attached to a custom-designed constant-stress Inconel cantilever test beam using a high-temperature capable Al 2 O 3 -based adhesive. The beam was mounted in a box furnace and exposed to vibrations using a stainless-steel rod attached to a vibration generator outside the furnace. Here, the resulting measurements at high-temperatures reported in this paper confirm the viability of the MSAWR sensor to detect both vibration frequency and magnitude for high temperature industrial, defense, aerospace, and power sector applications.

42 ENGINEERING↗

Instruction manual model 600F, data transmission test set

Information necessary for the operation and maintenance of the Model 600F Data Transmission Test Set is presented. A description is contained of the physical and functional characteristics; pertinent installation data; instructions for operating the equipment; general and detailed principles of operation; preventive and corrective maintenance procedures; and block, logic, and component layout diagrams of the equipment and its major component assemblies.

Source record↗

Dynamic Analysis of Hybrid Energy Systems under Flexible Operation and Variable Renewable Generation -- Part I: Dynamic Performance Analysis and Part II: Dynamic Cost

Dynamic analysis of hybrid energy systems (HES) under flexible operation and variable renewable generation is considered in order to better understand various challenges and opportunities associated with the high system variability arising from the integration of renewable energy into the power grid. Unique consequences are addressed by devising advanced HES solutions in which multiple forms of energy commodities, such as electricity and chemical products, may be exchanged. Dynamic models of various unit operations are developed and integrated within two different HES options. One HES option, termed traditional, produces electricity only and consists of a primary heat generator (PHG) (e.g., a small modular reactor), a steam turbine generator, a wind farm, and a battery storage. The other HES option, termed advanced, includes not only the components present in the traditional option but also a chemical plant complex to repurpose excess energy for non-electricity services, such as for the production of chemical goods (e.g., transportation fuel). In either case, a given HES is connected to the power grid at a point of common coupling and requested to deliver a certain electricity generation profile as dictated by a regional power grid operator based on a predicted demand curve. Dynamic analysis of these highly-coupled HES are performed to identify their key dynamical properties and limitations and to prescribe solutions for best managing and mitigating the high variability introduced from incorporating renewable energy into the energy mix. A comparative dynamic cost analysis is also conducted to determine best HES options. The cost function includes a set of metrics for computing fixed costs, such as fixed operations and maintenance (O&M) and overnight capital costs, and also variable operational costs, such as cost of variability, variable O&M cost, and cost of environmental impact, together with revenues. Assuming different options for implementing PHG (e.g., natural gas, coal, nuclear), preliminary results identify the level of renewable penetration at which a given advanced HES option (e.g., a nuclear hybrid) becomes increasingly more economical than a traditional electricity-only generation solution. Conditions are also revealed under which carbon resources may be better utilized as carbon sources for chemical production rather than as combustion material for electricity generation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Requirements for Prognostic Health Management of Passive Components in Advanced Small Modular Reactors

Advanced small modular reactors (aSMRs), which are based on modularization of advanced reactor concepts, may provide a longer-term alternative to traditional light-water reactors and near term small modular reactors (SMRs), which are based on integral pressurized water reactor (iPWR) concepts. aSMRs are conceived for applications in remote locations and for diverse missions that include providing process or district heating, water desalination, and hydrogen production. Several challenges exist with respect to cost-effective operations and maintenance (O&M) of aSMRs, including the impacts of aggressive operating environments and modularity, and limiting these costs and staffing needs will be essential to ensuring the economic feasibility of aSMR deployment. In this regard, prognostic health management (PHM) systems have the potential to play a vital role in supporting the deployment of aSMR systems. This paper identifies requirements and technical gaps associated with implementation of PHM systems for passive aSMR components.

Nondestructive Evaluation↗

Enhancement of Optical Efficiency of CSP Mirrors for Reducing O&M Cost via Near-Continuous Operation of Self-Cleaning Electrodynamic Screens (EDS). Final Report

Over the past decade, techno-economical advancements in solar energy systems, particularly the improvement in the conversion efficiency of PV modules made with mono-crystalline silicon solar cells from 12% to 20%, as well as the cost reduction in manufacturing by a factor of about 10%, have made it possible to achieve a levelized cost of electricity (LCOE) in PV plants that is comparable to, or less than, the cost of deriving electricity from fossil fuels. Operating PV plants in mid-latitude sun-belt regions, where the solar irradiance level is highest, provides a high annual energy-yield (kWh/kWp) due to two factors: (1) the availability of predictable high solar irradiance throughout the year with the fewest interruptions in solar flux from clouds and rain, and (2) the increased conversion efficiency of crystalline solar cells, as recombination loss has decreased with increased intensity of the sunlight that illuminates the silicon solar cells. Semi-arid and desert regions, however, are plagued by high atmospheric dust concentrations and frequent sand storms. The deposition of a layer of dust on the optical surfaces of solar collectors such as PV modules and concentrating mirrors reduces the transmission efficiency of sunlight that actually reaches the solar cells or receivers, resulting in high energy-yield soiling loss. There are two major cost components to operating a solar plant: (1) installation costs, and (2) operation-and-maintenance (O&M) costs. There is no fuel cost; hence operating a solar plant in a semi-arid or desert region provides high returns on investment if soiling losses are mitigated via efficient cleaning methods and optimized cleaning frequency. If solar collectors are not cleaned, the accumulation of dust layers on solar collectors may cause the operation of such plants in arid regions to become economically unviable. Washing solar collectors with water and detergent, as is most commonly done now, is an efficient method for cleaning. The conventional approach in utility-scale solar plants is to use a large truck with a water tank and pump system for spraying deionized water on the surface of the solar collectors. Robotic cleaning with brushes, used for many solar plants, requires lesser water for cleaning. The water consumed using semi-automated cleaning of PV modules in utility-scale solar plants is approximately 2 liters/m 2 per cleaning cycle. The total optical surface area of the solar collectors in 1 TW-scale solar installation will be more than 3 × 109 m 2 ; hence an enormous amount of water be needed for cleaning. There simply is not enough fresh water in the sun-belt areas of the world for predicted cleaning needs. In solar power plants, the estimated cost of cleaning solar collectors includes expenses related to the equipment used, labor, cost of transportation of water, the energy required for cleaning, plus ancillary costs whereas the cost of water is not considered. The water used is obtained from sources located close to plant sites, unmindful of the environmental and societal impact as the power plants are oftentimes located in regions that face severe drought. This practice is very similar to the cost calculations in deriving the levelized cost of electricity (LCOE) in conventional power plants based on burning fossil fuel such as coal and gas, while disregarding the cost of climate change and health effects. Unless a water-free or low-water cleaning method is established, the expansion of solar plants may lose public support in areas suffering long intervals of drought. The goal of this research project has been the development and application of the Electrodynamic Screen (EDS) as a means for a water-free, scalable cleaning process applicable to solar-power installations, including rooftop applications. We describe here the development of an EDS film-based cleaning process as an emerging method for use on PV modules, parabolic troughs, and heliostats. This report aims to show the feasibility of integrating or retrofitting EDS films onto the optical surfaces of solar collectors (both PV and CSP) while maintaining high transmission or reflection efficiency. The cleaning action provided by the EDS film is an active method to remove dust deposits by electrodynamic force. Current lab-scale prototype EDS films, retrofitted onto solar panels and mirrors, have shown to be capable of maintaining optical transmission or specular-reflection efficiencies higher than 90% of initial values under clean conditions. The optical surfaces of solar collectors laminated with EDS films can remove more than 90% of deposited dust when the EDS is activated for less than two minutes. As an electrodynamic dust removal process, the EDS film-based method is designed primarily for the removal of dust in solar installations located in semi-arid and desert areas, where the atmosphere is often dry and dusty and rainfall is infrequent. While EDS film application minimizes water consumption and facilitates cleaning as frequently as needed, it has limitations in removing contaminants such as soot, organic pollutants deposited as fine films on the surface, and bird droppings. The dust removal efficiency of the EDS is maximum at relative humidity RH is 40 to 50% and decreases at when RH > 65%. Many solar plant sites undergo diurnal and seasonal cycles of high ambient, early afternoon temperatures and an RH that reaches the dew point early in the morning. These variations in atmospheric conditions do not limit the operation of the EDS film. This report presents a brief review of the progress and the potential of EDS film technology for mitigating the impact of dust on solar collectors via water-free cleaning, as well as current technical challenges regarding efficiency and durability. Our experimental data on the performance of EDS films show that: (1) the dust-removal efficiency (DRE) can reach levels higher than 90%, (2) the specular reflectivity (SR) of EDS film-laminated second-surface mirrors reach levels in excess of 90%, (3) the specular reflectivity restoration (SRR) can exceed 90%, (4) the output-power restoration (OPR) of PV modules can exceed 95%, and (5) the optical transmission efficiency (TE) of the EDS films can be greater than 90%. Working with Sandia National Laboratories (NM), Corning Research and Development Corporation (NY), Eastman Kodak (NY), Tomark-Worthen Industries (NH), and EDS Chile SPA (Chile), we have produced EDS film-laminated PV modules and demonstrated their self-cleaning functions without requiring water. We have demonstrated that the operational range of EDS films will cover the expected ambient temperature of solar fields at RH cycling varying from 20 to 95% as long as the EDS films are activated in the RH range 20 to 50%. (Typical solar-field climates in deserts and semi-arid lands often reach near dew point in coastal areas.) Our experiments on the application of hydrophobic-fluorinated nanoparticle coatings on EDS film surfaces show that the EDS operational range can be extended to higher RH levels that approach the dew point. At Eastman Kodak, as one of our industrial partners, we were able to establish a process for manufacturing EDS films using flexographic printing of the electrodes onto transparent polymer films. This process utilizes an existing manufacturing line at Eastman Kodak that allows fabrication of medium-scale EDS films (26 cm × 30 cm). The manufacturing process has the capacity to produce EDS films at high production speeds. The medium-scale EDS films that have been printed at Kodak were evaluated in the lab at Boston University. The EDS films produced at Kodak were laminated at Tomark-Worthen using an industrial scale vacuum laminator to produce EDS film stacks, which can be affixed onto the optical surfaces of PV modules or concentrating mirrors. The EDS film stack consists of the EDS films that have Willow® Glass (WG) which has a thickness of 100 μm as the front surface. The WG sheets obtained from Corning Research and Development Corporation are customized in size and shape to cover the active area of the EDS films. The back surface of the EDS film stack is integrated onto the optical surface of the solar panel or mirror using optically clear adhesive (OCA) films or silicone adhesives. The OCA films (thickness 25 μm) are produced by 3M. The EDS film stacks have the architecture: WG/OCA/EDS Film/OCA/ over PV module or solar mirror. The power-supply units needed for activating the electrodes of the EDS film were designed and produced at Boston University. These power supply units provide three-phase, 1.2 kV voltage pulses at a very low current (micro-ampere) level and at a low frequency (≈ 5 Hz). The voltage pulses are applied to the electrodes in a sequence such that the train of pulses resembles a unidirectional traveling wave of electrical field on the surface of the EDS film. The dust particles on the surface become charged electrostatically and are levitated by the Coulomb force. The lateral sweeping action of the traveling electric field created by the three-phase voltages pulses then sweeps the dust off the surface. The energy consumed by the EDS electrodes is less than 0.2 Wh/m 2 /cleaning cycle, enabling energy-efficient restoration of output power (OPR) of PV module or specular reflectivity restoration (SRR) for solar mirrors. The EDS system consists of (1) an EDS film stack laminated onto the solar collectors, (2) connection of the EDS film to its power supply unit and (3) Interconnection of the power supply to PV modules or solar mirrors. Design, construction and assessment of field-testing units that have EDS stack laminated PV modules for evaluating the performance of the EDS films in solar fields is being carried out at BU. Our progress under this project, aimed at the advancement of EDS film technology, has reached DOE Technology Readiness Level (TRL) 6. Based on the extensive laboratory evaluations and limited field trials, as well as contacts with potential users, we believe that the technology has reached its commercial stage. We are conducting a cost analysis using the National Renewable Energy Laboratory (NREL) System Advisory Model (SAM) and are preparing for field trials of EDS films in different solar fields in the US, Chile, India and in the Middle East. A brief description of EDS film performance, construction and testing of the field-test unit, autonomous operation of the field-test unit for evaluating EDS performance in increasing energy yield, associated revenue savings, and water conservation is presented.

14 SOLAR ENERGY↗

Procedure Visualization to Augment Space Mission Training

The Intelligent Virtual Station (IVS) has been developed by the Smart Systems Research Laboratory at the NASA Ames Research Center as a solution to some of the training and operations challenges faced by organizations like the International Space Station training facilities and Mission Control engineering teams. At present, astronaut crews are constrained by limited access to physical mockups, which themselves have a built-in 1-g limitation. Mission operations team are faced with the daunting task of controlling the operations and maintenance of an ever-changing Station in space. Many operations teams create and follow textual procedures without the ability to visualize the given actions or alternatives. The NS allows users to easily generate and view procedures to enhance training and operations. Because training and mission operations are of crucial importance to the International Space Station and other similarly sophisticated programs, this paper is focused on the NS integrated procedure tool.

McIntosh, Dawn M.↗

Panel Session 26: Risk-Based Approaches to Environmental Remediation and Adaptive Site Management

This panel discussed the needs and importance of developing risk-based approaches to environmental remediation that will enable complex sites to be adaptively managed by applying cost-effective remedies that are protective of human health and the environment. The discussion emphasized risk-based approaches within decision processes and subsequent incorporation into regulatory decision documents. Remedy approaches, remediation exit strategies, and long-term monitoring plans that support risk-based end-states for difficult-to-remediate sites were discussed Panelists with presentations: Risk-Informed Approaches to Environmental Remediation and Adaptive Site Management (Vicky Freedman); ITRC Adaptive Site Management Perspective (Michael Truex); Optimization During Operations and Maintenance Phase at the Hanford Site 200-ZP-1 Groundwater Operable Unit (Emerald Laija, Kate Amrhein, Michael Truex); Adaptive Management: EPA Overview (Benjamin Simes); Decommissioning and Environmental Remediation Section Division of Nuclear Fuel Cycle and Waste Technology (Horst Monken Fernandes)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Wireless Interrogation of High Temperature Surface Acoustic Wave Dynamic Strain Sensor

Dynamic strain sensing is necessary for high-temperature harsh-environment applications, including powerplants, oil wells, aerospace, and metal manufacturing. Monitoring dynamic strain is important for structural health monitoring and condition-based maintenance in order to guarantee safety, increase process efficiency, and reduce operation and maintenance costs. Sensing in high-temperature (HT), harsh-environments (HE) comes with challenges including mounting and packaging, sensor stability, and data acquisition and processing. Wireless sensor operation at HT is desirable because it reduces the complexity of the sensor connection, increases reliability, and reduces costs. Surface acoustic wave resonators (SAWRs) are compact, can operate wirelessly and battery-free, and have been shown to operate above 1000°C, making them a potential option for HT HE dynamic strain sensing. This paper presents wirelessly interrogated SAWR dynamic strain sensors operating around 288.8MHz at room temperature and tested up to 400°C. The SAWRs were calibrated with a high-temperature wired commercial strain gauge. The sensors were mounted onto a tapered-type Inconel constant stress beam and the assembly was tested inside a box furnace. The SAWR sensitivity to dynamic strain excitation at 25°C, 100°C, and 400°C was .439 μV/με, 0.363μV/με, and .136 μV/με, respectively. Furthermore, the experimental outcomes verified that inductive coupled wirelessly interrogated SAWRs can be successfully used for dynamic strain sensing up to 400°C.

47 OTHER INSTRUMENTATION↗

Development of Event-Based Data Acquisition for Acoustic Emission Monitoring of the Structural Integrity of Wind Turbine Blades [Slides]

DOE Alignment: Reduce the cost of floating offshore wind energy in deep waters to $45/MWh by 2035 from today’s estimated $150/MWh20 by: Developing operations and maintenance strategies and increasing wind turbine reliability to reduce periods of non-operation and reduce labor at sea through remote system health monitoring, inspection, and maintenance capabilities incorporating artificial intelligence and predictive maintenance.

17 WIND ENERGY↗

Nuclear Power Fault Diagnostics and Preventative Maintenance Optimization

The nuclear industry is beginning to see reactors shut down—even after their operating licenses have been extended—because they are not economically competitive with other energy sources. These early closures happen primarily due to economic reasons, despite excellent safety records. Therefore, it is imperative to reduce costs in order to prevent these early closures. One of the contributors to these economic reasons is the large operations and maintenance costs. This paper showcases recent research on advanced fault diagnostics techniques and preventative maintenance optimization (PMO) for reducing NPP maintenance costs. Specifically, it focuses on the feedwater and condensate system (FWCS) for both pressurized- and boiling-water reactor (BWR) systems. The computerized maintenance management system (CMMS), which contains the plant’s digital record of all corrective maintenance (CM) and preventative maintenance (PM) work orders, provided the ground truth for locating potential faults and labeling the process data as either healthy or faulted. Various feature extraction techniques were used to further differentiate the faulted data from the healthy data. Through a cross-validation procedure, support vectors machines were used to label other test sets of process data as either healthy or faulted. With relatively few faults identified in the BWR system, the potential for PMO opens up, since an unnecessary amount of PM leads to inflated maintenance costs. The steps for PMO are summarized, from component health determinations to recommendations for action. An example of PMO assessment is presented for condensate pumps, condensate booster pumps, and the respective motors that drive them.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Analytics-at-scale of Sensor Data for Digital Monitoring in Nuclear Plants: 2nd Annual Report

For economic reasons, the nuclear industry is witnessing premature closure of nuclear power plants, despite excellent safety records. Operations and Maintenance (O&M) activities are some of the largest costs in operating legacy light-water plants. By reducing O&M costs, nuclear energy can become more economically competitive with other energy sources. This can be achieved by leveraging machine-learning and artificial intelligence technologies to develop data-driven algorithms to better diagnose potential faults within the system. Improved accuracy of the models can lead to a reduction in unnecessary maintenance, thus reducing costs associated with parts, labor, and unnecessary planned, forced, or extended outages. To address these challenges, the goal of this project is to perform research and development in the area of digital monitoring, i.e., the application of advanced sensor technologies (particularly wireless sensor technologies) and data science based analytic capabilities, to advance online monitoring and predictive maintenance in nuclear plants and improve plant performance (efficiency gain and economic competitiveness). This report summarizes the fiscal year 2020 research progress encompassing (1) different wireless vibration sensor and data indicators used to assess the health of a plant asset; (2) development of diagnostic models for fault detection; and (3) development of prognostic models for estimating the health of the system up to 7 days ahead.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Specifications of FIPD Fission Gas Release Data

All fission gas release data stored in the Fuels Irradiation & Physics Database (FIPD) was originally measured using the Gas Assay, Sample and Recharge (GASR) System in the Hot Fuel Examination Facility (HFEF). It is therefore called GASR data in FIPD. During the measurement of a sample, such as an irradiated EBR-II fuel element/capsule, a pinhole-sized region near the top of the element plenum was melted by a laser. Plenum gas then expanded into a calibrated volume (note: in this document, “sample” and “capsule/element” are used interchangeably consistent with GASR documents in FIPD). The pressure rise in the volume was recorded. Helium backfilling and expansion was then performed to determine the sample (e.g., fuel element plenum) volume using Boyle’s Law and assuming ideal gas behavior at constant temperature. With the plenum volume and the recorded pressure rise, the sample (e.g., fuel element plenum) pressure was derived with assumption of ideal gas law behavior. The plenum volume and pressure as well as the cladding temperature during the measurement were collected (GASR data in FIPD). Other records associated with the fission gas release data include: raw GASR data records including volumes and post-puncture pressures of seal head/sealing head and manifold, calibration data, backfilling gas pressure data, and the data analysis records. A sample(s) of the fission gas released from the plenum was collected by the GASR system into sample bottles. The chemical and isotopic composition of the gas sample was analyzed separately from GASR data, and will be discussed in a separate specification. The plenum volume, pressure, and cladding temperature during the measurement are typically utilized to determine the number of moles of gas in the plenum. This quantity is often compared to the number of moles of gas generated by fission events. However, calculating these values and their associated uncertainty is beyond the scope of this document, as it necessitates additional assumptions. The most important document to understand the FIPD fission gas data is the GASR operational manual (title: Gas Assay, Sample and Recharge System (GASR) operation and maintenance manual, HFEF/N OMM 4381, DOC. NO. W0018-0032-ES-00). This manual provides: (1) description of the GASR and the functions of each component (laser drilling, welding, seal head/sealing head, manifold, vacuum system, sample system, purge and gas tag system, etc.); (2) step-by-step guidance on calibrations, operations, and measurements; and (3) maintenance procedures and other details relating to the structure and operation of the GASR. Note that the original GASR operated until 2020. A new GASR with the same design and measurement methodology was installed in 2021. The specifications of the GASR presented on the HFEF website at this time are consistent with the ones given in the operational manual. The methods to calculate the plenum volume and pressures were not included in the operational manual, but were recorded in the legacy data analysis files. Details of the methods are given in Chapter 3.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Wireless online position monitoring of manual valve types for plant configuration management in nuclear power plants

In the current competitive energy market, the nuclear industry is committed to lower the operations and maintenance cost; increase productivity and efficiency while maintaining safe and reliable operation. The present operating model of nuclear power plants is dependent on large technical staffs that put the nuclear industry at long-term economic disadvantage. Technology can play a key role in nuclear power plant configuration management in offsetting labor costs by automating manually performed plant activities. The technology being developed, tested, and demonstrated in this paper will enable the continued safe operation of today’s fleet of light water reactors by providing the technical means to monitor components in plants today that are only routinely monitored through manual activities. The wireless enabled valve position indicators that are the subject of this paper are able to provide a valid position indication available continuously, rather than only periodically. As a result, a real-time (online) availability of valve positions using an affordable technologies are vital to plant configuration when compared with long-term labor rates, and provide information that can be used for a variety of plant engineering, maintenance, and management applications.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Non-destructive structural characterization of graphite components using mechanical resonance and deep learning

As compared to conventional nuclear reactors, microreactors have the potential to significantly reduce construction timelines and capital costs, decreasing the barriers for advanced nuclear reactor technologies. However, the lower power output of these microreactors (typically < 20 MWe) creates challenging economics if operation and maintenance costs cannot be sufficiently reduced. The compact size of these designs presents an opportunity for comprehensive in-situ structural health monitoring to provide real-time feedback in order to reduce operational costs associated with maintenance and downtime. Many microreactor concepts use graphite for both in-core neutron moderation and as a structural material, which has typically required some form of periodic and laborious inspection. This report provides a description and assessment of recent work with graphite to couple acoustic-based experimental measurements and characterization with machine learning models to mature structural health monitoring capabilities and generate benefits for the nuclear microreactor industry. With resilient embedded sensors in development in other programs funded by the US Department of Energy’s Office of Nuclear Energy and elsewhere, the work described herein builds upon previously funded efforts to mature non-destructive testing technology that relates measured vibrational signatures to structural changes, using a combination of new experimental measurements and machine learning processing. Building on past successful demonstrations of predictive workflows to identify structural changes in a hexagonal stainless steel test article with excellent acoustic propagation, we first performed baseline characterization on graphite samples with canonical geometries to ensure compatibility and confidence in the applied techniques for a material with distinctly different mechanical properties. In contrast to efforts in previous years, we worked exclusively with unidirectional vibration data that is more comparable to those expected from the existing embedded sensor technologies which are suitable for deployment in a reactor setting. Established acoustic and modern machine-learning-based characterization approaches were applied to the resulting datasets from these simple geometries. Both approaches were found to be highly capable of detecting even small geometric irregularities amongst nominally identical samples. As such, we then moved to testing these approaches for detection of artificial local stress perturbations introduced into a more complex geometry: a hexagonal block with drilled holes. A main outcome of this work is that a generalizable ML workflow can be used to detect and predict the characteristics of small artificial anomalies in a graphite component with a relevant geometry. While this work was performed using surficial vibration data, we expect the approach to be flexible and viable for other monitoring scenarios, such as those with different arrangements or types of sensor arrays. As compared to previously funded efforts, an existing ML workflow based on neural networks was enhanced through the addition of recently developed Fourier neural operators. As applied to previously collected and new vibration datasets, prediction accuracies of anomaly characterizations were greatly improved with minimal added computational cost. As trained on small durations of vibration data (tens of seconds) collected over a realistic number of locations, the model was able to reliably determine the presence of a subtle stress anomaly and begin to provide location estimates. Such an approach is likely to be viable for more relevant reactor damage scenarios for graphite components, such as progressive crack growth or creep.

36 MATERIALS SCIENCE↗