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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Eddy current flow meter model validation with a moving solid rod*

We report that the eddy current flow meter (ECFM) has been used to measure velocities and temperatures of conductive flows, such as liquid metal flows in a nuclear fission reactor. The goal of this paper is to develop a finite element electromagnetic model that can characterize the ECFM sensor performance and validate this finite element model with detailed velocity measurements of a controlled, well-characterized moving conductive solid rod. Both measurements and modeling were performed for various parameters that are important for ECFM performance such as rod velocity, rod material, ECFM sensor coil length, number of sensor coils, applied alternating current (AC) current amplitude, and applied ECFM AC frequency. For all parametric scans, the measurement and modeling agree well in both magnitude and trend. The normalized root-mean-square error between measurement and modeling is less than 10% for all cases. These results suggest that electromagnetic modeling could eventually be used to cost-effectively design future ECFM sensors in arbitrary geometry for more challenging applications such as liquid metal nuclear fission reactors.

47 OTHER INSTRUMENTATION↗
DOE OSTI2018

Automated Glovebox Work-cell Design - 18370

Los Alamos National Laboratory (LANL) is the primary plutonium science and manufacturing facility in the United States supporting multiple national security programs. It is responsible for completing a high variety of small-batch manufacturing tasks requiring the handling and precision machining of Special Nuclear Materials (SNM). Given the myriad of tasks that must be completed in a limited workspace, LANL intends to utilize flexible, multi-use robotic work-cells capable of completing a variety of mission critical tasks in a single glovebox with no re-tooling needed between batch jobs. This approach would allow LANL more flexibility in its production schedule and to meet its future production and research objectives. In this paper, we present a system that integrates multiple sensors and other manufacturing peripherals into existing glovebox infrastructure. Currently, a technician can place an object in the work area where vision sensors and supervisory software identify the object and its pose and automatically determine which manufacturing task to complete. Pose uncertainty is addressed in real-time by the task planner, eliminating the need for fixtures. Grasps are validated using pressure sensors, payload sensors, and grasp quality metrics to ensure that objects are not dropped or damaged during manipulation. The robot, sensors, and peripherals are controlled using open-source software built utilizing ROS (Robot Operating System), which minimizes redevelopment and allows for re-use and extensibility. Established capabilities support vision, collision-free path planning, and more, minimizing development time. For this effort, particular attention was given to the integration of general peripheral devices (drill, chuck, etc.), which is critical to efficiently utilizing ROS in manufacturing environments. This integration is achieved with an in-development framework that allows for quick integration of peripherals, including I/O devices and motors. Contact tasks utilize the Generalized Contact Control Framework (GCCF) previously developed at UT Austin. GCCF allows application developers to easily define multiple contact control tasks for a single robot. This paper summarizes the key software components necessary to develop the multi-use work-cell including existing ROS components. UT-developed software for grasp validation, peripheral integration, and contact control is presented in more depth. Finally the glovebox system is demonstrated completing a set of tasks with no fixturing necessary. Primary tasks include surface preparation/ablation, drilling, press-fitting, and sorting, as well as supporting material transfer and inspection tasks. The glovebox work-cell reduces cost, operator dose, ergonomic issues, and time loss due to material transfer between gloveboxes that only support one task. If multiple glovebox work-cells are in use, they have the potential to eliminate bottlenecks and scale production capabilities beyond current limits. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

Accurate determination of density, surface tension, and vessel depth using a triple bubbler system

Here, a triple bubbler sensor was developed for use in high temperature molten salt systems used in pyroprocessing to determine the density, surface tension, and depth of the molten salt. Preliminary bubbler testing was performed in aqueous solutions to calibrate and validate the bubbler sensor. Independently determined fluid property values and depths were compared to the calculated values and the percent differences were less than 0.16 %, 3.38 %, and 0.31 % for density, surface tension, and depth, respectively. In addition, uncertainties were within 0.04 %, 1.25 %, and 0.15 % for density, surface tension, and depth, respectively.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2023

Development, Testing, and Validation of Fabry-Pérot Cavity Acoustic Sensors for Microreactor Applications

Nuclear microreactors are a unique reactor design which may allow for the nuclear energy industry to tap into unconventional markets, and their modularity presents some advantages over larger, conventional reactor designs. For nuclear microreactors to be economically viable, on-line structural health monitoring may be necessary to reduce operation and maintenance costs with lower power production. Optical fiber sensors, and specifically optical Fabry-Pérot cavities (FPCs), may present the opportunity to monitor vibrational frequencies of microreactor components during operation, enabling identification of the location and severity of potential damage. In this work, FPCs were designed and fabricated with materials which may be able to survive in the extremely harsh environment of nuclear microreactors. The FPCs were bonded to metal test specimens to monitor their vibrational frequencies, along with a reference piezoelectric accelerometer. Euler-Bernoulli theory was used to calculate the fundamental modes and mode-shapes to compare with experimentally measured frequency spectra. The peak frequencies detected with the FPC and piezoelectric accelerometer, and theoretical modes, all agreed well for the first four fundamental modes (within 5%). Furthermore, when the FPC and accelerometer were co-located on the test specimen, their peak frequencies all agreed within 1%.

Birri, Tony↗
DOE OSTI2016

Simultaneous moisture content and mass flow measurements in wood chip flows using coupled dielectric and impact sensors

An 8-electrode capacitance tomography (ECT) sensor was built and used to measure moisture content (MC) and mass flow of pine chip flows. The device was capable of directly measuring total water quantity in a sample but was sensitive to both dry matter and moisture, and therefore required a second measurement of mass flow to calculate MC. Two means of calculating the mass flow were used: the first being an impact sensor to measure total mass flow, and the second a volumetric approach based on measuring total area occupied by wood in images generated using the capacitance sensor’s tomographic mode. Tests were made on 109 groups of wood chips ranging in moisture content from 14% to 120% (dry basis) and wet weight of 280 to 1100 g. Sixty groups were randomly selected as a calibration set, and the remaining were used for validation of the sensor’s performance. For the combined capacitance/force transducer system, root mean square errors of prediction (RMSEP) for wet mass flow and moisture content were 13.42% and 16.61%, respectively. RMSEP using the combined volumetric mass flow/capacitance sensor for dry mass flow and moisture content were 22.89% and 24.16%, respectively. Either of the approaches was concluded to be feasible for prediction of moisture content in pine chip flows, but combining the impact and capacitance sensors was easier to implement. As a result, in situations where flows could not be impeded, however, the tomographic approach would likely be more useful.

09 BIOMASS FUELS↗
DOE OSTI2018

Self-Navigating Robotic Assistant for Long-term Wide Area Floor Contamination Monitoring - 18213

For Routine Contamination Testing (RCT) of an operational nuclear facility or one undergoing Decontamination and Decommissioning (D and D), workers utilize specified travel corridors (enclosed hallways or areas designated with tape or rope in open spaces) to minimize the risk of spreading contamination. Radiation health technicians must continually monitor these areas for contamination to minimize worker dose and prevent its spread to uncontrolled areas. For many sites, it is impractical for the technician to adequately survey such areas. The Nuclear Robotics Group (NRG) at UT Austin has developed a self-navigating robotic platform equipped with radiation detectors to augment the technician to improve both survey coverage and frequency. While maintaining a controlled velocity and floor-to-sensor distance, the system takes radiation measurements to identify and/or localize contamination sources. Readings above background levels are reported to a remote workstation to allow technicians to then respond accordingly. The completion of these mundane tasks by a robot allows the trained technicians to focus instead on operational tasks, D and D, or responding to alarms. The robot generates a map using a Lidar range sensor with established Simultaneous Localization and Mapping (SLAM) techniques. Range data is then compared to previously generated maps for robot localization and autonomous navigation. To maximize coverage, the robot executes a Complete Coverage Path Planning (CCPP) algorithm using a static map that is discretized into cells to assure comprehensive yet efficient coverage. As the system executes the generated plan, it builds a radiation map of the area for the technician to validate and verify the results. If contamination is detected, the robot will minimize the spread of contamination by stopping, sounding an alarm, and alerting the remote technician. The proposed system allows for long-term deployment with minimal human intervention. It is robust to both highly dynamic obstacles (i.e. personnel) and low dynamic changes (i.e. temporally stored cart) in the environment. This is accomplished through continuous spatiotemporal updating of the static map, and the utilization of a supervisory controller that allows the system to reliably respond to unexpected events or states (i.e. low battery, closed door, etc.). While the supervisory controller can respond to temporary complications, the system also recognizes the environment can change slowly over time necessitating that the CCPP automatically be updated to account for observed 'permanent' changes to the environment. To do this, the robot uses intermediate probabilistic data to make intelligent planning decisions offline while still maintaining local reactive obstacle avoidance and safety features. The self-updating of the map allows the robot to run longer without the need to remake the map, leading to more consistent monitoring data and less maintenance from the human technician. This paper will review the current system hardware, the CCPP algorithm, the supervisory controller, the probabilistic algorithm for identifying permanent changes, and recent experiments at UT Austin to experimentally validate the reported sensor coverage. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Pressure-Driven Fiber-Optic Sensor for Online Corrosion Monitoring

For many industrial applications, corrosion is a life-limiting phenomenon and therefore requires careful consideration and rigorous experimental testing before structural materials can be reliably deployed, particularly in harsh chemical environments. The traditional approach to measuring corrosion requires exposing many samples to the intended environment and then extracting them individually at discrete intervals for postexposure characterization. This approach does not provide a high degree of temporal resolution, nor does it provide any real-time information regarding dynamic changes in corrosion rates. Additionally, developing an online corrosion monitor capable of surviving harsh chemical environments could provide valuable information regarding the structural health of components and changing process conditions that could accelerate corrosion. To this end, a corrosion sensor was developed based on a pressure-driven Fabry-Pérot cavity (FPC). This sensor uses a pressure control system to internally pressurize the FPC formed between the sensor’s housing and a metal-embedded singlemode optical fiber. Simultaneous measurement of the change in FPC length using low-coherence interferometry and the applied pressure enables the calculation of the relative changes in the sensor’s diaphragm thickness due to corrosion on its outer surface. Measurements were made in situ while actively corroding the sensor and were validated against surveillance specimens that were corroded simultaneously. The uncertainties in the measured corrosion were analyzed using error propagation of the uncertainties in the measured pressures and displacements and were found to be <1% of the initial diaphragm thickness.

42 ENGINEERING↗
DOE OSTI2025

Precision Timing in CMS at the HL-LHC: Current Progress on Validation and Production

During the High Luminosity phase of LHC, up to 200 proton-proton collisions per bunch crossing will bring severe challenges for event reconstruction. To mitigate pileup effects, an extended upgrade program of the CMS experiment is expected. Among which, a new timing layer, the MIP Timing Detector (MTD), will be integrated between the tracker and the calorimeters. With a time resolution of 30-60 ps, the MTD will enable 4D vertexing, bringing significant improvements in track-to-vertex association and object identification. The MTD is composed of two subsystems based on different technologies: the Barrel Timing Layer (BTL) consists of LYSO:Ce scintillating crystals readout by SiPMs, and the Endcap Timing Layer (ETL) is made of Low-Gain Avalanche Diodes. The BTL is currently under production, while ETL sensor prototyping and validation are ongoing. Recent system tests have confirmed the performance of the full acquisition chain. This talk will provide an overview of the MTD design, along with the physics motivation, and the current status of BTL construction and ETL development.

Safdari, Murtaza [Fermilab] (ORCID:000000018323731↗
DOE OSTI2026

Grid Topology Discovery Algorithm Evaluation of Suitability for Utility Deployment (CRADA 606 Final Report)

This work presents the results of a field-informed demonstration aimed at evaluating the practical suitability of a topology discovery algorithm for utility environments. We demonstrated an algorithm that uses a graph-theory-informed state estimation approach for model selection. In collaboration with Survalent and Peninsula Light Co., the algorithm was applied to real feeder models and field measurements from supervisory control and data acquisition (SCADA) and advanced metering infrastructure (AMI) systems to identify the operational topology of a power distribution system. The demonstration assessed the algorithm’s performance under realistic data conditions, including sparse and noisy measurements, and examined its ability to identify the most likely network configurations. The results confirmed that the approach can effectively narrow down feasible topologies, providing operators with improved situational awareness of network status. Key lessons learned emphasize the need for systematic data validation and strategic sensor placement to enhance observability. These insights inform future deployment strategies and guide refinements for broader adoption in utility operations.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Distributed Coaxial Cable Sensors for In-Situ Condition Based Monitoring of Coal-Fired Boiler Tubes

The increasing contributions of renewable energy sources present new challenges to the operation and maintenance of the existing coal-fired power plants. One of the major operational risks is the unexpected failure of superheater boiler tubes, leading to the most unplanned power plant outrages. The boiler tube failure is difficult to predict due to the harsh operating environments. Therefore, condition-based monitoring (CBM) with a reliable high temperature sensor becomes necessary to produce a meaningful assessment of the health condition of boiler tubes and their remaining lifetime. In this work, the stainless-steel and quartz coaxial cable sensor (SSQ-CCS) is proposed for in-situ distributed monitoring of the boiler tube temperatures in existing coal-fired power plants. Comprehensive tests have been conducted with an in-house testing facility at Clemson University to study and evaluate the sensors’ performance in the temperature range of 100℃ to 600℃. The results indicated that the measurement resolution of the SSQ-CCS sensor is better than 1℃, and the drift is less than 2% over long-period testing. Meanwhile, multi-physics finite element analysis has been conducted to optimize the design and evaluate the safety of the SSQ-CCS temperature sensor under various operational conditions. Based on the performance obtained in the laboratory-scale testing, a field test has been implemented at a power plant. Four SSQ-CCS temperature sensors were installed for in-situ monitoring of the temperatures of a power plant’s superheat tube assembles. The data acquisition system has been successfully set up and collected sensing signals for more than three months. The sensing signals have been post-processed, and the monitored temperature history through the SSQ-CCS temperature sensor has been validated and compared with the conventional high temperature thermal couple data.

Jiao, Xinyu↗
DOE OSTI2020

Development of risk mitigation guidance for sensor placement inside mechanically ventilated enclosures – Phase 1

Guidance on Sensor Placement was identified as the top research priority for hydrogen sensors at the 2018 HySafe Research Priority Workshop on hydrogen safety in the category Mitigation, Sensors, Hazard Prevention, and Risk Reduction. This paper discusses the initial steps (Phase 1) to develop such guidance for mechanically ventilated enclosures. This work was initiated as an international collaborative effort to respond to emerging market needs related to the design and deployment equipment for hydrogen infrastructure that is often installed in individual equipment cabinets or ventilated enclosures. The ultimate objective of this effort is to develop guidance for an optimal sensor placement such that, when integrated into a facility design and operation, will allow earlier detection at lower levels of incipient leaks, leading to significant hazard reduction. Reliable and consistent early warning of hydrogen leaks will allow for the risk mitigation by reducing or even eliminating the probability of escalation of small leaks into large and uncontrolled events. To address this issue, a study of a real-world mechanically ventilated enclosure containing GH2 equipment was conducted, where CFD modeling of the hydrogen dispersion (performed by AVT and UQTR, and independently by the JRC) was validated by the NREL Sensor laboratory using a Hydrogen Wide Area Monitor (HyWAM) consisting of a 10-point gas and temperature measurement analyzer. In the release test, helium was used as a hydrogen surrogate. Expansion of indoor releases to other larger facilities (including parking structures, vehicle maintenance facilities and potentially tunnels) and incorporation into QRA tools, such as HyRAM is planned for Phase 2. It is anticipated that results of this work will be used to inform national and international standards such as NFPA 2 Hydrogen Technologies Code, Canadian Hydrogen Installation Code (CHIC) and relevant ISO/TC 197 and CEN documents.

08 HYDROGEN↗
DOE OSTI2021

A zone-level occupancy counting system for commercial office spaces using low-resolution time-of-flight sensors

Understanding the locations of occupants in a commercial built environment is critical for realizing energy savings by delivering lighting, heating, and cooling only where it is needed. In this paper, we present an indoor occupancy counting system using a sparse array of inexpensive, low-resolution, and privacy-preserving time-of-flight sensors. We develop and validate an algorithm for zonal occupancy counting that can deal with multiple people walking underneath the sensors in arbitrary directions, and evaluate the system both in realistic simulations of office spaces and in a real-world installation. Finally, we found that our system has an error rate of around 0.4%, resulting in highly accurate person localization and zone counting using only a few sensors per space.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

One-Step Ahead Prediction of Thermal Mixing Tee Sensors with Long Short Term Memory (LSTM) Neural Networks

High-temperature advanced reactors under development, such as sodium fast reactors (SFR) and molten salt cooled reactors (MSCR), are expected to offer lower levelized cost of energy (LCOE) compared to existing light water reactor (LWR’s). In the existing light water reactors (LWR’s), operation and maintenance (O&M) expenses constitute the largest fraction of the total operating cost. Some of the O&M costs are related maintenance of sensors which can fail due to exposure to harsh environment in a reactor. The O&M costs of Advanced Reactor (AR)’s are expected to constitute a significant fraction of the total cost as well, because of high temperature and radiation level in AR are likely to cause material fatigue and premature failure of sensors and components. The O&M costs in AR’s could be reduced through integration of advanced informatics of performance-related sensors into a digital twin designed for reactor monitoring. For example, machine learning (ML) could be employed for real-time validation and correction of performance-related sensors, and reducing the number of performance-related physical sensor units through virtual sensing. As part of the effort, we investigate real-time validation of thermal hydraulic sensors through one-step ahead forecasting of sensor values using long short-term memory (LSTM) recurrent neural networks (RNN). The sensors are installed in a flow loop containing a thermal mixing tee, which is a common experimental model to study thermal fatigue in a thermal hydraulic loop. In addition, nonlinear transients generated in a thermal mixing tee constitute a good challenge data set for training and validation of ML algorithms. Sensors in this study include thermocouples, flow meters, and optical fibers for distributed temperature sensing. In one experiment, measurement data sets were obtained for a loop was filled with water, and in another experiment, measurements were performed on a loop filled with liquid metal Galinstan. We have also conducted preliminary investigation of one-step ahead prediction of fiber optics-based distributed temperature sensing with LSTM networks. In predicting fiber-based temperature measurements, we treated each gauge pitch of the fiber as an independent sensor. Accuracy of one-step ahead forecasting was estimated by calculating root mean square error (RMSE) for the test segment of time series of each sensor. RMSE’s for temperature sensors in water loop were, for the most part, lower than for the same sensors in Galinstan loop. The RMSE’s for flow meters were similar for both loops. The RMSE’s for distributed temperature measured with the fiber optic sensor were similar to those of the point sensors. Results of this study demonstrated the capability of LSTM one-step ahead forecasting with RMSE comparable to uncertainty in sensor measurements.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Heterogeneous Integration Technologies for High-temperature, High-density, Low-profile Power Modules of Wide Bandgap Devices in Electric Drive Applications (Final Technical Report)

The goal of this project is to develop packaging technologies for making high-temperature, high-density, and low-profile wide-bandgap (WBG) power electronics modules for electric drives. These modules are aimed at enabling the DOE’s University Consortium to reach its 2025 inverter targets of ≥ 100 kW/L and ≤ 2.7 $/kW. The specific objectives are to: design and fabricate SiC half-bridge power modules with double-sided cooling and parasitic inductances < 5 nH, heat flux density > 400 W/cm 2 , and working junction temperature of 200 o C; design, fabricate, and deliver a gate driver with double-sided cooled modules for the construction of a 100 kW/L inverter at Oak Ridge National Lab; and design and prototype intelligent gate drivers with integrated current sensor and a low-profile DC-DC power supply with air-core transformer for testing power modules at 200 o C junction temperature. We followed an iterative technical approach of design, simulation, fabrication, and testing of various versions of modules, current sensors, and power supply. The state-of-the-art silicon carbide devices rated at 1.2 kV and 149 A were packaged by sintered-silver bonding on an aluminum nitride direct-bond-copper substrate for high thermal conductivity, high working temperature, and high joint reliability. Porous silver posts were used to interconnect the device’s source pads to the other direct-bond-copper substrate for low mechanical stresses, ease of manufacturing, and double-sided cooling. A current sensor based on package parasitic inductance was developed to measure switching current. A dynamic feedback scheme was developed to compensate the effect of parasitic resistance and temperature variation. A constant-current class-E dc-dc converter with air-core transformer was developed. Air-core transformer was used due to the unavailability of magnetic core at high temperatures. Gate driver and power supply were integrated with the double-side cooled, high temperature SiC power modules for testing the modules at 200 o C junction temperature. Double-pulse and continuous testing of the integrated technologies validated the design and fabrication of the three component technologies. Throughout the project, we overcame the challenge for design verification caused by low prototyping yield, which then helped train the graduate students, the future workforce, to learn the engineering know-how for low-cost manufacturing of reliable products. Below is a summary of the major accomplishments of this project: development of a prototyping process for fabricating double-side cooled (1200 V, 149 A) SiC phase-leg modules capable of working to 200 o C Tj; simulation and experimental verification of the improvement of thermo-mechanical reliability of the double-side cooled SiC phase-leg module by using rigid encapsulant; design and experimental validation of a current sensor based on package parasitic inductance and a compensation solution for eliminating the effect of parasitic resistance; design and experimental validation of a low-profile power supply with six-output air-core transformer for gate driver; functional demonstration of a SiC phase-leg module integrated with its gate driver, current sensor, and an air-core power supply at 200 o C Tj in a double-pulse switching test setup and Buck converter continuous test setup; successful completion of six PhD and two MS students who are or will work at Apple Inc., Tesla Inc., Wolfspeed Inc., Microchip Inc., Monolithic Power Systems Inc., and LG Magna Inc.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2016

Sensor sentinel computing device

Technologies pertaining to authenticating data output by sensors in an industrial environment are described herein. A sensor sentinel computing device receives time-series data from a sensor by way of a wireline connection. The sensor sentinel computing device generates a validation signal that is a function of the time-series signal. The sensor sentinel computing device then transmits the validation signal to a programmable logic controller in the industrial environment.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2016

Development of Electrical Capacitance Sensors for Accident Tolerant Fuel (ATF) Testing at the Transient Reactor Test (TREAT) Facility

A variety of instruments are being developed and qualified to support the Accident Tolerant Fuels (ATF) program and future transient irradiations at the Transient Reactor Test (TREAT) facility at Idaho National Laboratory (INL). The University of New Mexico (UNM) is working with INL to develop capacitance-based void sensors for determining the timing of critical boiling phenomena in static capsule fuel testing and the volume-averaged void fraction in flow-boiling in-pile water loop fuel testing. The static capsule sensor developed at INL is a plate-type configuration, while UNM is utilizing a ring-type capacitance sensor. Each sensor design has been theoretically and experimentally investigated at INL and UNM. Experiments are being performed at INL in an autoclave to investigate the performance of these sensors under representative Pressurized Water Reactor (PWR) conditions in a static capsule. Experiments have been performed at UNM using air-water two-phase flow to determine the sensitivity and time response of the capacitance sensor under a flow boiling configuration. Initial measurements from the capacitance sensor have demonstrated the validity of the concept to enable real-time measurement of void fraction. The next steps include designing the cabling interface with the flow loop at UNM for Reactivity Initiated Accident (RIA) ATF testing at TREAT and further characterization of the measurement response for each sensor under varying conditions by experiments and modeling.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗