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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 109 records · Page 6

Performance of Microreactor Test Article with Embedded Sensors During Testing in The Single Primary Heat Extraction and Removal Emulator

The nuclear industry is pursuing microreactors that can be factory assembled and deployed to remote regions for reliable power generation. One class of microreactors uses a monolithic metal core block coupled to heat pipes that use passive heat flow, increasing the surface area for heat transfer without requiring active coolant flow through the reactor core. Additional experimental testing is required to understand the heat rejection limitations of heat pipes and thermal stresses in the monolithic core block due to significant temperature gradients. This report describes the initial characterization and testing of a stainless-steel test article that was fabricated with embedded sensors to measure heat pipe performance limits, as well as spatially distributed temperatures and strains during electrically heated thermal testing to simulate nuclear heating. The electrically heated testing was performed in the Single Primary Heat Extraction and Removal Emulator facility located at Idaho National Laboratory. The ultimate goals of this work are to (1) accurately monitor temperature and strain distributions that result from differential thermal expansion in the test articles and (2) quantify the heat rejection limits of heat pipes as a function of operating temperature and working fluid during steady-state and transient operations. Initial tests focused on the feasibility of using advanced fiber-optic sensors and other sensor technologies to improve the understanding of temperature and strain distributions within the electrically heated experiments. However, these sensing capabilities could benefit the broader microreactor community if the sensors could be used to monitor component and system health during nuclear operations to inform a limited number of microreactor operators, ultimately reducing operation and maintenance costs and moving toward semiautonomous operation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Distributed sensing of electromagnetic components using optical fiber based methods

An OFDR based fiber-optics sensor for distributed real-time temperature rise monitoring of a transformer in operation has been disclosed. The fiber-optic sensor provides an effective solution to monitoring the physical structures of the transformer core, as well as accurately detecting the non-uniform temperature distribution inside the transformer, and thus provides innovative feedback to the transformer design by minimizing the core losses. Additionally, the method may be responsive to the presence of magnetic and electric fields, as well as responsive to various chemical species. The method allows novel approaches to real-time asset monitoring of power transformers while operational.

Ohodnicki, Paul R.↗

A simple algorithm for beam profile diagnostics using a thermographic camera

A new algorithm for digital image processing apparatuses is developed to evaluate profiles of high-intensity DC beams from temperature images of irradiated thin foils. Numerical analyses are performed to examine the reliability of the algorithm. To simulate the temperature images acquired by a thermographic camera, temperature distributions are numerically calculated for 20 MeV proton beams with different parameters. Noise in the temperature images which is added by the camera sensor is also simulated to account for its effect. Using the algorithm, beam profiles are evaluated from the simulated temperature images and compared with exact solutions. We find that niobium is an appropriate material for the thin foil used in the diagnostic system. We also confirm that the algorithm is adaptable over a wide beam current range of 0.11–214 μA, even when employing a general-purpose thermographic camera with rather high noise (ΔT{sub NETD} ≃ 0.3 K; NETD: noise equivalent temperature difference)

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Load monitoring and compensation strategies for guided-waves based structural health monitoring using piezoelectric transducers

Accurate interpretation of in-situ piezoelectric sensor signals is a challenging task. This article presents the development of a numerical compensation model based on physical insight to address the influence of structural loads on piezo-sensor signals. The model requires knowledge of in-situ strain and temperature distribution in a structure while acquiring sensor signals. The parameters of the numerical model are obtained using experiments on flat aluminum plate under uniaxial tensile loading. It is shown that the model parameters obtained experimentally can be used for different structures, and sensor layout. Furthermore, the combined effects of load and temperature on the piezo-sensor response are also investigated and it is observed that both of these factors have a coupled effect on the sensor signals. It is proposed to obtain compensation model parameters under a range of operating temperatures to address this coupling effect. An important outcome of this study is a new load monitoring concept using in-situ piezoelectric sensor signals to track changes in the load paths in a structure.

environmental compensation↗

Recovery Act: Federspiel Controls (now Vigilent) and State of California Department of General Services Data Center Energy Efficient Cooling Control Demonstration. Final technical project report

Eight State of California data centers were equipped with an intelligent energy management system to evaluate the effectiveness, energy savings, dollar savings and benefits that arise when powerful artificial intelligence-based technology measures, monitors and actively controls cooling operations. Control software, wireless sensors and mesh networks were used at all sites. Most sites used variable frequency drives as well. The system dynamically adjusts temperature and airflow on the fly by analyzing real-time demands, thermal behavior and historical data collected on site. Taking into account the chaotic interrelationships of hundreds to thousands of variables in a data center, the system optimizes the temperature distribution across a facility while also intelligently balancing loads, outputs, and airflow. The overall project will provide a reduction in energy consumption of more than 2.3 million kWh each year, which translates to $240,000 saved and a reduction of 1.58 million pounds of carbon emissions. Across all sites, the cooling energy consumption was reduced by 41%. The average reduction in energy savings across all the sites that use VFDs is higher at 58%. Before this case study, all eight data centers ran the cooling fans at 100% capacity all of the time. Because of the new technology, cooling fans run at the optimum fan speed maintaining stable air equilibrium while also expending the least amount of electricity. With lower fan speeds, the life of the capital investment made on cooling equipment improves, and the cooling capacity of the data center increases. This case study depicts a rare technological feat: The same process and technology worked cost effectively in eight very different environments. The results show that savings were achieved in centers with diverse specifications for the sizes, ages and types of cooling equipment. The percentage of cooling energy reduction ranged from 19% to 78% while keeping temperatures substantially within the limits recommended by the American Society of Heating, Refrigeration, and Air-Conditioning Engineers (ASHRAE) for data center facilities.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Evaluation of Optical Fiber Bragg Gratings in a Nuclear Reactor

Optical fiber-based sensors are capable of distributed temperature and/or strain measurements with high accuracy and sub-cm spatial resolution. Optical fibers have a small diameter ({approx}100 {mu}m), a small mass (and therefore fast response time), and are fabricated from high temperature-tolerant, radiation-hard materials. These qualities make optical fiber-based instrumentation a promising candidate for in-pile sensing applications, monitoring fuel performance during irradiation in test reactors, or embedding fibers in other commercial reactor components or structures. The Department of Energy and Idaho National Laboratory are restarting the TREAT reactor (Transient Reactor Test facility) and are interested in updating the reactor's instrumentation regarding the analysis of the test fuel. The ability of optical fibers to make distributed temperature measurements coupled with its small footprint makes optical fiber a viable candidate to monitor fuel performance in the TREAT reactor. The work presented in this paper focuses on the radiation hardness of various types of optical fiber Bragg gratings. Previous experiments have shown that the inscription of Bragg gratings into optical fiber can extend the radiation survivability of distributed sensing in optical fibers, and so the goal is to determine which types of Bragg gratings survive the best in a reactor environment.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Sensor Qualification for the Development of Advanced Reactors

A temperature sensor qualification device is undergoing development and testing in order to qualify temperature sensors for advanced reactor metrology applications. This device will provide National Institute of Standards and Technology (NIST) traceable performance testing of temperature sensors while under the high radiation environments experienced while in-core. This is completed by utilizing retractable sensors which transfer the measurements from ex-core to in-core sensors. A detailed discussion of the uncertainty propagation associated with this comparative process is provided. Experimental testing of the temperature distribution occurring in the device has begun and is reported on. It is pertinent to minimize this temperature distribution to prevent variation in sensor measurements. This variation will be indistinguishable from sensor drift for in-pile applications and would result in unnecessarily conservative uncertainty bounds.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗

Temperature Mapping analysis of Nitrogen-doped Niobium Radio Frequency Cavity

Nitrogen-doping of niobium superconducting radio-frequency (SRF) cavity has been shown to significantly improve the quality factors as compared to the standard treated niobium cavities. However, the nitrogen-doped cavities generally quench at lower accelerating gradients. To understand the possible sources of rf losses in nitrogen-doped cavities that could reduce the quench field, we used 576 thermometer sensors to map the temperature distribution of the outer cavity surface while increasing the accelerating field. Our measurements have revealed a strong effect of the cavity cooldown rate on the intensity of hot spots and their spatial distribution, indicating a significant contribution from trapped vortices on the RF losses.

Makita, Junki↗

Characterization of Temperature Heterogeneity in Utility-Scale Power Plant Boilers by Spatially Distributed Ultrasonic Measurements

In extreme environments, even hardened insertion sensors fail quickly. For such environments, we have developed an ultrasonic (US) method for measuring the spatial distribution of temperatures in solid materials and, specifically, across containments of extreme processes. By deploying US sensors in multiple locations, spatial heterogeneity in temperatures inside harsh environments may be characterized. In this note, we update our progress on testing the developed approach in an industrial setting and its performance in describing the temperature distribution inside a 500 MW (electrical) coalfired utility boiler of an electrical power generation plant. We use waveguides (WG) structured to contain echogenic features that produce a train of echoes in response to an excitation pulse. The time of flight between echoes encodes the information on the temperature distribution in the corresponding segment of the WG, which we reconstruct using its parametrization. Five waveguides were welded to the boiler’s heat exchange surface (waterwall) and different locations at the same boiler elevation and produced reliable US waveforms 18 months after the installation. For several weeks during the latest trial, we performed US measurements in five locations spanning half of the boiler’s 14-meter width. The measurements were acquired during regular operation, including load cycling to adjust for demand and intermittent contributions of renewable power sources, and during boiler shutdown for emergency maintenance and the subsequent restart. The interpretation of US waveforms by signal processing resulted in an accurate estimation of temperature distribution along the waveguides. We captured daily cyclical variations in demand-following load. Measurements performed in multiple locations revealed unexpected temperature variations across the boiler. We conclude that an array of developed sensors can provide responsive and spatial temperature measurements while maintaining functionality despite prolonged exposure to an extreme environment.

Walton, Kenneth↗

Machine-Learning Enabled Evaluation of Probability of Piping Degradation In Secondary Systems of Nuclear Power Plants

The transition to condition-based, risk-informed automated maintenance will contribute to a significant reduction of operations and maintenance costs that account for the majority of nuclear power generation costs. Furthermore, of the operations and maintenance costs in U.S. plants, approximately 80% are labor costs. To address the issue of rising operating costs and economic viability, technologies used to perform online monitoring of piping and other secondary system structural components in commercial nuclear power plants (NPPs) are under evaluation. These online monitoring systems have the potential to identify when a more detailed inspection is needed using real time measurements, rather than at a pre-determined inspection interval thus reducing the maintenance cost. This paper describes distributed high-temperature stable fiber sensors fabricated in optical fibers through a roll-to-roll laser direct writing process using femtosecond lasers. Using phase-sensitive optical time domain reflectometry, distributed acoustic and vibration sensors can be developed and deployed to critical components and systems in NPPs to perform active measurements with spatial resolution down to 0.5-meter throughout the piping systems. Complex acoustic and vibration signatures harnessed by distributed sensors are registered and analyzed by artificial intelligence algorithms for degradation detection and flaw identification. Piping elbows with machined-in flaws were instrumented with fiber sensors. High-spatial-resolution data were used to develop and validate machine learning algorithms, including both linear and nonlinear regression, and classification. Additionally, classification and sensor analysis were also performed for data analysis. The paper concludes with recommendations and future work on applications of machine learning enabled high-resolution fiber sensors for piping degradation monitoring in current or future NPPs.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Robust Ceramic Coaxial Cable Down-Hole Sensors for Long-Term In Situ Monitoring of Geologic CO 2 Injection and Storage

Energy generation by use of fossil fuels produces large volumes of CO 2 and other greenhouse gases, whose accumulation in the atmosphere is widely seen as undesirable. CO 2 Capture followed by sequestration has been identified as the solution. Subsurface geologic formations offer a potential location for long-term storage of CO 2 because of their requisite size. Unfortunately, the inaccessibility and complexity of the subsurface, the wide range of scales of variability, and the coupled nonlinear processes, impose tremendous challenges to determine the transport and predict the fate of the stored CO 2 . Among the various monitoring approaches, in situ down-hole monitoring of the various state parameters provides critical and direct data points that can be used to validate the models, optimize the injection, detect leakage and track the CO 2 plume. However, down-hole sensors that can withstand the harsh conditions and operate over decades of the project lifecycle remain unavailable. Given that the widespread of carbon capture and storage will be the necessity and reality in the future, fundamental and applied research is required to address the significant challenges and technological gaps in lack of long-term reliable down-hole sensors This project focused on the development and demonstration of a novel, low-cost, distributed, robust ceramic coaxial cable sensor platform for in situ down-hole monitoring of geologic CO 2 injection and storage with high spatial and temporal resolutions. The coaxial cable Fabry-Perot interferometer (CCFPI) has been studied as a general sensor platform for in situ, long-term, measurement of temperature, pressure and strain, which are critical to CO 2 injection and storage. A novel signal processing scheme has been developed and demonstrated for dense multiplexing of the sensors for low-cost distributed sensing with high spatial resolution. The developed temperature, pressure and strain sensors have been extensively tested under laboratory conditions that are similar to the downhole CO 2 storage environment, showing excellent capability for in situ monitoring the various parameters that are important to model, optimize the injection, detect leakage and track the CO 2 plume. In addition, the interactions between the sensor datum and the geological models have been investigated in details for the purposes of model validation, guiding sensor installation/placement, enhancement of model prediction capability and optimization of the injection processes. This project has resulted in the successful development of new ceramic coaxial cable based sensor systems that can monitor directly the changes in pressure, temperature, and strain caused by increased reservoir pressure and reduced reservoir temperature due to the supercritical CO 2 injection. Integrated with geological models, the sensors and measurement data can improve the possibility to identify plume movement and leakage in the cap rock and wells with higher precision and more accuracy. The low cost, ease of deployment, small size and dense multiplexing features of the new sensing technology will allow a large number of sensors to be deployed to address the objective to demonstrate that 99% of the CO 2 remains in the injection zone.

01 COAL, LIGNITE, AND PEAT↗

Abstract for CRADA between National Energy Technology Laboratory and Colonial Pipeline Company

The National Energy Technology Laboratory (NETL) and Colonial Pipeline Company (Participant) will collaborate in the field demonstration of optical fiber sensor systems developed at NETL on Participant’s fuel pipeline. The optical fiber sensor technologies are capable of distributed temperature and strain sensing, distributed acoustic sensing, and ultrasensitive acoustic sensing. Real-time monitoring of these parameters enables pipeline integrity monitoring, security monitoring, flow rate monitoring, etc. Successful demonstration on a real fuel pipeline at Participant’s facilities will validate the sensor technologies and installation methods at a real scale. This effort aligns with NETL’s mission in reliable and sustainable energy and reducing environmental effects due to pipeline failures.

42 ENGINEERING↗

Multiplexable intrinsic Fabry-Pérot interferometers inscribed by femtosecond laser for vibration measurement in high temperature environments

This article reports fabrication technique and demodulation algorithm developments to use multiplexable intrinsic Fabry-Pérot interferometer (IFPI) fiber sensor array for distributed vibration measurements at high temperatures. Using femtosecond laser direct writing scheme, IFPI array were fabricated through laser-induced Type II scattering points in single mode fiber cores. Reflection spectra of IFPI array were demodulated in real-time using modified Bunemen frequency analysis. The demodulation algorithm, which was implemented using a photodetector-array spectrometer, achieves 64-nε dynamic strain resolution at 1-kHz spectral acquisition rate and 2-kHz maximum vibration bandwidth. Performance and stabilities of IFPI sensor array were characterized from room temperatures to 800 °C. The static strain resolution was 0.6 με and the minimum detectable dynamic strain amplitude was 23 nε/√Hz at 800 °C. The multiplex performance was also tested by measuring dynamic strain in time domain through six IFPI sensor array fabricated in one fiber. This paper presents an integrated and low-cost sensing solution to perform distributed vibration measurements in harsh environments.

42 ENGINEERING↗

Dynamic Heat Flow and Current Distribution Analysis in the Bottom Anode of an Electric Arc Furnace Using Fiber-Optic Sensors

A reliable method for monitoring bottom anode wear during DC Electric Arc Furnace (DC-EAF) operation is of critical importance for safe and efficient steel production. Underestimation of bottom wear poses a serious safety risk that must be avoided, while overestimation of bottom wear also poses challenges, as premature anode replacement is expensive and affects EAF productivity. Previously, we demonstrated that fiber-optic sensors can be successfully deployed to create a spatially distributed temperature map to monitor the health of the anode. The present work explores the heat flow and current density distribution in bottom anode pins to predict bottom wear, steel penetration events, and monitor refractory erosion. Small dynamic variations in pin temperature induced by joule heating during arcing also provide a means to observe local current flows in each pin. When mapped, these measurements provide a real-time view of the non-uniform and dynamic current flow in the bottom anode during EAF operation that can affect bottom wear.

Bottom Anode↗

Development of coated heat flux gauges for fast responding measurements

Thermal systems often exhibit transient behaviors that have important implications for the operation of the system and can be difficult to predict. For these reasons, experimental testing is often required to ensure system durability requirements are achieved. One important parameter governing the survivability of components in hot, high-stress environments is the heat flux into the part that dictates the temperature distribution for the component. However, sensors required to experimentally characterize heat fluxes in extreme environments must also be resilient. Here, this study presents the development of coated heat transfer gauges capable of robust, high-frequency measurements in turbine research facilities. The addition of a protective coating increases the durability of the gauge, but inherent of that coating is the attenuation of high-frequency temperature penetrations. As a result, this study first outlines the use of analytical solutions to define a gauge design for a specific frequency range and heat transfer, ensuring that subsurface signals can be rectified to surface conditions through inverse methods. Then, the fabrication of polyimide substrate sensors with a parylene-F coating is described. Micro surface heaters added to the custom sensors were used to determine important geometric and thermal properties necessary to calculate accurate surface heat flux. Ultimately, this work shows increased sensor robustness in a turbine test bed and experimentally validates that the frequency response of the fabricated sensors meet the design intent.

47 OTHER INSTRUMENTATION↗

Distributed Brillouin fiber laser sensor

Brillouin fiber sensors can provide distributed strain and temperature measurements over long distances in standard off-the-shelf fiber by measuring the Brillouin frequency shift as a function of position along a fiber. The primary drawback of these systems is their limited sensitivity, which results from the challenge in identifying the Brillouin frequency shift to within a small fraction of the Brillouin linewidth. In this work, we introduce a technique that overcomes this fundamental limitation by establishing a series of lasing modes that experience Brillouin amplification at discrete spatial locations in the test fiber. The linewidth narrowing and high intensity associated with the lasing transition enable precise measurements of this lasing frequency. As an initial demonstration, we present a sensor that simultaneously excites 40 lasing modes in a 400 m fiber, providing a measurement of the strain at 40 discrete locations with a spatial resolution of 4 m. Each sensor exhibits a minimum detectable strain as low as 4 nε/Hz 1/2 with a dynamic range of >5 mε and a bandwidth of ~10 kHz. As the first demonstration that Brillouin lasing can be used for distributed fiber sensing, this work establishes an approach that could enable ultra-high strain sensitivity using off-the-shelf fiber.

47 OTHER INSTRUMENTATION↗

Nonnuclear Experimental Capabilities to Support Design, Development, and Demonstration of Microreactors

This work provides a summary of selected experimental capabilities being developed to support nonnuclear testing and demonstration of technology in support of microreactors under the U.S. Department of Energy’s (DOE’s) Microreactor Program. Major capabilities include the Single Primary Heat Extraction and Removal Emulator (SPHERE) and the Microreactor Agile Non-nuclear Experimental Test Bed (MAGNET). The SPHERE facility allows for controlled testing of the steady-state and transient heat rejection capabilities of a single heat pipe using electrical heaters that simulate nuclear heating. The facility is capable of monitoring axial temperature profiles along the heat pipe and surrounding test articles during startup, steady-state operation, and transients. Instrumentation includes noncontact infrared thermal imaging, surface thermocouples, spatially distributed fiber optic temperature and strain sensors, electrical power meters, and a water-cooled, gas-gap calorimeter for quantifying heat rejection from the heat pipe. The facility can be operated under both vacuum and inert-gas conditions. The MAGNET facility is a large-scale, 250-kW electrically heated microreactor test bed to enable nonnuclear experimental evaluation of a variety of microreactor concepts. It can be supplied to electrically heat a scaled section of a microreactor and further test the capabilities of heat rejection systems. The initial MAGNET experiments will support technology maturation and reduce uncertainty and risk associated with the design, operation, and deployment of monolithic heat pipe–based reactors. However, this test bed can broadly be applied to multiple microreactor concepts to evaluate a wide range of thermal-hydraulic and structural phenomena such as interface coupling with power conversion units and other collocated systems. MAGNET can evaluate integral thermomechanical effects during electrical heating of an array of heat pipes in a larger test article. Examples of initial testing will include thermal stresses in the monolith and the impact of debonding of a heat pipe from the core block and how that failure could impact surrounding heat pipes, i.e., understanding the potential for cascading failure. This work also discusses some modeling capabilities that can support experiment design, analysis, and interpretation, including the heat pipe code Sockeye and a comparison of thermal-structural simulations performed using ABAQUS and STAR-CCM+.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗