Components and sub-assemblies SNAP 8 radiation effects test program, volume III
Irradiation testing of electronic components and subassemblies in Radiation Effects Reactor
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Irradiation testing of electronic components and subassemblies in Radiation Effects Reactor
Report details study made of nondestructive radiographic, ultrasonic, thermographic, and leak test methods used to inspect and evaluate the quality of the various brazed joints in liquid-propellant rocket engine components and assemblies. Descriptions of some of the unique equipment and methods developed are included.
Component level testing of power conversion units proposed for use in fission surface power systems has typically been done using relatively simple electric heaters for thermal input. These heaters do not adequately represent the geometry or response of proposed reactors. As testing of fission surface power systems transitions from the component level to the system level it becomes necessary to more accurately replicate these reactors using reactor simulators. The Direct Drive Gas-Brayton Power Conversion Unit test activity at the NASA Glenn Research Center integrates a reactor simulator with an existing Brayton test rig. The response of the reactor simulator to a change in Brayton shaft speed is shown as well as the response of the Brayton to an insertion of reactivity, corresponding to a drum reconfiguration. The lessons learned from these tests can be used to improve the design of future reactor simulators which can be used in system level fission surface power tests.
The Mechanical Impulse Pyro Shock (MIPS) Simulator at GE Astro Space Division is one version of a design that is in limited use throughout the aerospace industry, and is typically used for component shock testing at levels up to 10,000 response g's. Modifications to the force imput, table and component boundary conditions have allowed a range of test conditions to be achieved. Twelve different designs of components with weights up to 23 Kg are in the process or have completed qualification testing in the Dynamic Simulation Lab at GE in Valley Forge, Pa. A summary of the experience gained through the use of this simulator is presented as well as examples of shock experiments that can be readily simulated at the GE Astro MIPS facility.
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Chartered in 1957 as a joint action agency of the state, Energy Northwest (ENW) is a consortium of 27 public utility districts and municipalities across Washington state. ENW takes advantage of economies of scale and shared services to help utilities run their operations more efficiently and at lower cost, to the benefit of more than 1.5 million customers. ENW develops, owns, and operates a diverse mix of electricity generating resources, including hydro, solar, and wind projects – and the Northwest’s only active nuclear energy facility. These projects provide enough reliable, affordable, and environmentally responsible energy to power more than a million homes each year, and that carbon-free electricity is provided at the cost of generation. The agency continually explores new generation projects to meet its members’ needs. In 2017, as part of the second round of funding from the Washington state Clean Energy Fund, the Washington State Department of Commerce granted up to $3 million in matching funds to develop an estimated $6.5 million project that deployed a 4-MW, 20-acre solar generating array of photovoltaic (PV) panels coupled with a 1 MW/5.5 MWh lithium-iron-phosphate battery energy storage system (BESS) in Richland, Washington. The combination of PV and BESS will provide a predictable, renewable generating source and will also serve as a training ground for solar and battery technicians throughout the nation. The City of Richland will purchase the power from the project and utilize the benefits of the energy storage. The project provides Washington state with its first opportunity to integrate a large-scale solar and storage facility into its clean mix of hydro, nuclear, and wind resources. This first-of-its-kind facility combines solar generation with battery storage and technician training. In 2019, Pacific Northwest National Laboratory (PNNL) worked with ENW to assess the integrated PV and BESS in representative use cases that could benefit the City of Richland. Between March and May 2022, extensive testing was conducted, and the results were used to assess the technical performance of the BESS subjected to actual field operations. Both reference performance and use case tests were performed: (A) Reference performance tests assess the general technical capabilities of the BESS, such as energy capacity, round-trip efficiency (RTE), ramp rate, and signal tracking capability. These are the first tests performed (baseline), and they are repeated after use case tests (post cycle). A standardized U.S. Department of Energy (DOE) energy storage performance protocol was used to characterize the BESS, including representative duty cycle profiles, test procedure guidance, and calculation guidance for determining key characteristics. (B) Use case tests examine the performance of the BESS for specific use cases using duty cycles developed by PNNL in collaboration with ENW. Five use cases were selected for testing: 1) demand charge reduction, 2) load shaping, 3) transmission charge reduction, 4) Volt-VAR service, and 5) outage mitigation. The use case duty cycles were developed based on utility and site-specific characteristics in addition to the technical characteristics and physical capabilities of the BESS. Use case tests were performed between the baseline and post cycle tests. This report describes the BESS and its components, presents testing and performance analysis results, and shares key insights and lessons learned from this project. Outcomes of the tests and analyses will help ENW understand the performance of the Horn Rapids BESS in its current state and design appropriate operational strategies for this and other BESSs over the long term.
Orcas Power & Light Cooperative (OPALCO) is a member-owned, nonprofit cooperative utility that provides energy services to approximately 11,200 customers across 20 islands in San Juan County, Washington. OPALCO’s mostly hydroelectric power is generated by Bonneville Power Administration and delivered to the islands by submarine cables. In 2016, as part of the second round of funding from the Washington state Clean Energy Fund, OPALCO received a $1 million matching grant to support a project that deployed a 504-kW LG community photovoltaic (PV) system in combination with a 1 MW/2 MWh lithium-iron-phosphate battery energy storage system (BESS) on Decatur Island, Washington. The Decatur Island Substation is essential to ensuring reliable energy for the residents of the San Juan Islands as it is the point of interconnection with the mainland transmission system. The BESS, in combination with the community solar array, will deliver an innovative method to both defer the costly upgrade of the transmission system and allow for other high-value applications intended to benefit the utility and its customers. In 2018, Pacific Northwest National Laboratory (PNNL) completed a preliminary economic assessment for several identified use cases in collaboration with OPALCO. Between August 2021 and May 2022, extensive testing was conducted, and the results were used to assess the technical performance of the BESS subjected to actual field operations. Both reference performance and use case tests were performed: (a) Reference performance tests assess the general technical capabilities of the BESS, such as energy capacity, round-trip efficiency (RTE), ramp rate, and signal tracking capability. These are the first tests performed (baseline) and are repeated after use case tests (post cycle). A standardized U.S. Department of Energy (DOE) energy storage performance protocol was used to characterize the BESS, including representative duty cycle profiles, test procedure guidance, and calculation guidance for determining key characteristics. (b) Use case tests examine the performance of the BESS for specific use cases using duty cycles developed by PNNL in collaboration with OPALCO. Four use cases were selected for testing: 1) demand charge reduction, 2) load shaping, 3) outage mitigation, and 4) transmission deferral. The use case duty cycles were developed based on utility and site-specific characteristics in addition to the technical characteristics and physical capabilities of the BESS. Use case tests were performed between the baseline and post cycle tests. This report describes the BESS and its components, presents testing and performance analysis results, and shares key insights and lessons learned from this project. Outcomes of the tests and analyses will help OPALCO understand the performance of the Decatur Island BESS in its current state and design appropriate operational strategies for this and other BESSs over the long term.
The National Reactor Innovation Center (NRIC) was created for accelerating the deployment of novel reactor concepts. This will be achieved by providing both physical and virtual spaces for building and testing various components, systems, and complete pilot plants. The Virtual Test Bed (VTB) represents the virtual arm. It is being developed in collaboration with Department of Energy’s (DOE) Nuclear Energy Advanced Modeling and Simulation (NEAMS) program.
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The Department of Energy (DOE) Office of Nuclear Energy National Reactor Innovation Center accelerates the deployment of novel reactor concepts by establishing both physical and virtual spaces for building and testing various components, systems, and complete pilot plants. The Virtual Test Bed represents the virtual arm of the National Reactor Innovation Center and is a joint effort with the DOE Nuclear Energy Advanced Modeling and Simulation Program. The Virtual Test Bed mission is to accelerate the deployment of advanced reactors by facilitating the adoption of cutting-edge DOE advanced modeling and simulation tools to design, evaluate, and license reactors. This is primarily achieved by storing example challenge problems in an externally available repository and by developing models to fill the M&S gaps needed for potential demonstrators. Activities conducted this fiscal year focused on developing of a Demonstration of Microreactor Experiments shield model to help accelerate the confirmatory analysis required for the reactor demonstration. This model and workflow will allow developers to leverage advanced modeling and simulation tools to ensure their reactor demonstration concept will meet dose requirements and that the surrounding shield will stay within concrete temperature limits during steady-state and transient operation conditions. An initial model has been developed to evaluate the temperature distribution in the concrete shield during steady-state operation, including neutron and gamma heating effects. Various modeling strategies have been examined to understand their applicability and limitations with different reactor designs to make the workflow as reactor-agnostic as possible and computationally effective to maximize its usability. In addition to describing the Demonstration of Microreactor Experiments shield model and associated results, this report summarizes other accomplishments regarding repository maintenance and improvement and new external models hosted on the repository.
The basic concepts of Strainrange Partitioning are reviewed, with particular reference to the areas requiring expanded verification. A cooperative program is proposed for achieving this broader verification through the additional experience provided by the participants in this program. The suggested program includes verification of the four basic life relationships (for PP, CC, PC, and CP type inelastic strainranges) for a variety of materials chosen by the participating organizations. The four relationships are then used in conjunction with the Interaction Damage Rule to predict the cyclic lives of tests involving various combinations of the basic strainrange components. The testing program also includes evaluation of the degree of insensitivity of these relationships to temperature as well as their utility in representing bounds on life.
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The specific aim was to develop within the Pilot Land Data System (PLDS) software design environment, an easily implementable and user friendly geometric correction procedure to readily enable the georeferencing of imagery data from the Advanced Very High Resolution Radiometer (AVHRR) onboard the NOAA series spacecraft. A software subsystem was developed within the guidelines set by the PLDS development environment utilizing NASA Goddard Space Flight Center (GSFC) Image Analysis Facility's (IAF's) Land Analysis Software (LAS) coding standards. The IAS current program development environment, the Transportable Applications Executive (TAE), operates under a VAX VMS operating system and was used as the user interface. A brief overview of the ICARUS algorithm that was implemented in the set of functions developed, is provided. The functional specifications decription is provided, and a list of the individual programs and directory names containing the source and executables installed in the IAF system are listed. A user guide is provided for the LAS system documentation format for the three functions developed.
The evaluation of a method for enhancing combustor hot-gas wall heat extraction by using hot-fire tests of a rocket engine combustor calorimeter with hot-gas wall ribs is presented. The capability for enhanced heat extraction is required to increase available turbine drive energy for high chamber pressure operation, and therefore higher overall expander cycle engine performance. Determination of the rib effectiveness for incorporation into the design of a high-performance combustor for an advanced expander cycle combustor intended for use in an orbital transfer vehicle or advanced space engine, was the objective of these tests.
The mini-dome Fresnel lens concentrator array, a high-efficiency, lightweight space photovoltaic array concept, is described. The three critical elements of the array concept are the Fresnel lens concentrator, the prismatic cell power cover, and the photovoltaic cell. Prototype concentrator lenses have been fabricated and tested, with optical efficiencies reaching 90 percent. Work is progressing on the design and fabrication of the panel structure. The impact of recent advances in 30 percent-efficient multijunction photovoltaic cells on array performance is also discussed. Near-term performance goals of 300 w/sq m and 100 w/kg are now feasible.
ATTAP activities were highlighted by test bed engine design and development activities; ceramic component design; materials and engine component characterization; ceramic component process development and fabrication; component rig testing; and test bed engine fabrication and testing. Specifically, ATTAP aims to develop and demonstrate the technology of structural ceramics that have the potential for competitive automotive engine life cycle cost and for operating for 3500 hours in a turbine engine environment at temperatures up to 1371 C (2500 F).
The Crew Exploration Vehicle (CEV) was intended to be the next-generation human spacecraft for the Constellation Program. The CEV Isolator Strut mechanism was designed to mitigate loads imparted to the CEV crew caused by the Thrust Oscillation (TO) phenomenon of the proposed Ares I Launch Vehicle (LV). The Isolator Strut was also designed to be compatible with Launch Abort (LA) contingencies and landing scenarios. Prototype struts were designed, built, and tested in component, sub-system, and system-level testing. The design of the strut, the results of the tests, and the conclusions and lessons learned from the program will be explored in this paper.