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DOE OSTI2023

Predicting Safety Rod Reactivity Insertion in the Advanced Test Reactor

The Advanced Test Reactor (ATR), and complimentary zero-power ATR Critical (ATRC) reactor, located at Idaho National Labs (INL), are undergoing conversion from Highly Enriched Uranium (HEU) to Low Enriched Uranium (LEU). Both have a variety of testing locations that can receive large variations in flux due to its unique serpentine design, consisting of five lobes surrounding nine flux traps (see Figure 1). Initial criticality and power distribution throughout the core are controlled by core-external outer shim control cylinders (OSCCs). Distinct test loops allow for testing at specific temperatures, pressures, and irradiation conditions such as flux and fission density. The ATR is one of the key nuclear engineering research and testing facilities within the DOE National Laboratory Complex, and the ATRC supports its operation [1]. Currently, the Office of Material Management and Minimization (M3) within the National Nuclear Security Administration of the DOE is working to convert the remaining research reactors, including the ATR, from 93% HEU fuel to 19.75% LEU fuel (LEU) to support non-proliferation [2]. Extensive materials testing at INL and internationally has demonstrated that a high-density uranium molybdenum (U 10Mo) alloy can meet the performance requirements of the remaining high powered research reactors. The current LEU fuel element design is named the LOWE element. However, there are many technical challenges to address before the conversion to LEU can be successful, including the accurate characterization of the reactor core physics with LEU fuel. To ensure safe operation of the ATR, reactor engineers prepare a CSAP (Core Safety Assurance Package) before each cycle. The purpose of the CSAP is to verify the reactor performance calculation used to determine if the selected fuel loading meets operational, experimental, and safety criteria. Many of the criteria in the CSAP are limits on reactivity insertion in various accident scenarios.

42 ENGINEERING↗

NASA NTRS2016

Impact of Automation Support on the Conflict Resolution Task in a Human-in-the-Loop Air Traffic Control Simulation

To determine the capabilities and limitations of human operators and automation in separation assurance roles, the second of three Human-in-the-Loop (HITL) part-task studies investigated air traffic controllers ability to detect and resolve conflicts under varying task sets, traffic densities, and run lengths. Operations remained within a single sector, staffed by a single controller, and explored, among other things, the controllers responsibility for conflict resolution with or without their involvement in the conflict detection task. Furthermore, these conditions were examined across two different traffic densities; 1x (current-day traffic) and a 20 increase above current-day traffic levels (1.2x). Analyses herein offer an examination of the conflict resolution strategies employed by controllers. In particular, data in the form of elapsed time between conflict detection and conflict resolution are used to assess if, and how, the controllers involvement in the conflict detection task affected the way in which they resolved traffic conflicts.

human-in-the-loop simulation↗

DOE OSTI2021

EXTRACTING HUMAN RELIABILITY FINDINGS FROM HUMAN FACTORS STUDIES IN THE HUMAN SYSTEMS SIMULATION LABORATORY

Modernization of U.S. nuclear power plants (NPPs) is widespread, with most plants currently replacing and transitioning equipment, control systems, and human system interfaces (HSI)s from analog to digital displays. This conversion remedies the obsolescence of analog parts along with needs for increased intuitiveness of design, safety, and capabilities. The Human Factors and Reliability team at Idaho National Laboratory (INL) carried out twelve control room modernization studies in the newly designed Human Systems Simulation Laboratory (HSSL) over nine years. The HSSL was constructed as a testbed for evaluating human factors techniques and performance measures, HSI frameworks, and cutting-edge operational concepts in NPPs. Installing a full-scope training simulator enabled direct design and evaluation work on the same instrumentation and control (I&C) and HSIs located at U.S. plants. The subsequent addition of glass top bays afforded crews opportunities to implement operations via the simulator using full-scale representations of their home NPP. Additionally, functional HSI prototypes were created, providing an environment for operator-in-the-loop benchmark studies. The HSSL has assisted in upgrades of six commercial NPP control rooms and served as an invaluable proving ground for new NPP operations technology. Human reliability analysis (HRA) was not originally the focus of the studies; however, data relating to HRA such as type and frequency of human errors can be extracted from the studies. INL is currently extracting data from the HSSL study reports to apprise how information gathered from simulation, HSI, and other related studies can create a broad look across different data sources to help inform HRA methods.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2023

Multiphysics Modeling of Hydrokinetic Turbine Energy Conversion System

Hydrokinetic turbines (HKTs) hold great promise as a renewable energy source, but high maintenance costs and limited energy output hinder their widespread adoption. The lack of comprehensive research on HKT drivetrain designs creates a knowledge gap in enhancing generation efficiency and cost reduction. A model of the HKT system with a focus on electric drivetrains and power converters is required to address this knowledge gap. This paper first introduces a MATLAB-averaged model integrating electrical-mechanical-thermal domains and aging behaviors within multi-time frames. Then a PLECS model, which incorporates maximum power point tracking and dq reference framed control for AC-DC-AC power converters, is enriched by a dynamic thermal model to predict fast transients accurately. These models optimize the design at the component level, resulting in improved integrated system performance. Furthermore, the validation of the models is carried out through hardware experiments for the averaged model and hardware-in-the-loop testing for the dynamic model.

ADVANCED PROPULSION SYSTEMS,HYDRO ENERGY↗

DOE OSTI2026

Urea-to-Ammonia Conversion at Proteus mirabilis Modified Pt–Ni/BDD Electrodes

Efficient wastewater recycling technologies are essential for long-duration space missions and sustainable water management on Earth. Here, a bioelectrochemical system integrating Proteus mirabilis with a platinum–nickel-modified boron-doped diamond electrode (Pt–Ni/BDDE) for urea-to-ammonia conversion in synthetic urine is presented. Immobilized P. mirabilis catalyzes enzymatic ureolysis, converting urea into ammonia, which is subsequently oxidized electrochemically, and no direct electrochemical urea oxidation is observed. Cyclic voltammetry (CV) of P. mirabilis on Pt–Ni/BDDE in 0.1 M urea and synthetic urine revealed a broad anodic oxidation peak at approximately 0.55–0.75 V vs Ag/AgCl (sat. KCl), corresponding to ammonia oxidation. Control experiments using bare BDDE and Pt–Ni/BDDE in synthetic urine showed no oxidation peak, establishing that the bioelectrocatalytic response originates exclusively from the bioelectrode interface. Chronoamperometry studies revealed that immobilization potential and time critically influenced bacterial adhesion and electrochemical response, with optimal conditions yielding a maximum current density of 0.0055 mA·cm –2 . These quantitative results establish that microbial ureolysis can be efficiently coupled with advanced electrode materials for urea-to-ammonia conversion, offering a promising self-sustaining strategy for urine processing and water recovery in closed-loop life support systems.

Ammonia↗

DOE OSTI2023

Cummins R-SOFC System Development

The overall purpose of this project was to reduce the Reversible-Solid Oxide Fuel Cell (R-SOFC) system cost by developing two technologies, an improved cell design and the incorporation of an ejector in the fuel recycle loop instead of a blower. A Simulink model of the baseline SOFC system was developed and calibrated with experimental test data. The R-SOFC system model was built by integrating GT Suite developed models of the steam generation components into the baseline Simulink SOFC system model. The ability to run the stack in SOEC operating mode was also added to the model. The system model was used to explore the ability of the R-SOFC system to meet operational constraints on Steam/Carbon ratio and H2 concentration on the fuel side electrode. A CFD ejector model was developed and used to explore a range of ejector design parameters, leading to the final ejector design that was prototyped for testing. A prototype steam ejector was first tested in a laboratory environment using room temperature air. The steam ejector was subsequently tested using the full hot recycle loop with all relevant heat exchangers and steam generation components. The test conditions utilized temperatures, pressures, and flow rates expected in an R-SOFC application. Throughout the experimental testing work, ejector performance test data was used to improve and then validate the CFD ejector model. A CFD cell model was developed and used to optimize thermal gradients, voltage, and cost of a new cell substrate design. A CFD comparison of co-flow and cross-flow cell designs informed the decision to use a co-flow design for the new cell substrate. Multiple rounds of CFD simulation were used to improve the cell design to minimize the variation in air and fuel distribution across cell channels and to minimize the variation in air and fuel distribution across different cells in the stack. A few prototypes of the new cell substrate design were produced and validated in a laboratory environment by thermally spraying and verifying that they met established manufacturing specifications. The cell manufacturing process was adjusted in order to bring these metrics within acceptable tolerances. Cummins’ internal calculations show that the new cell design reduces cost ~50% compared to the baseline cell, while the ejector + superheater/boiler concept reduces cost of the recycle loop by ~40%. The impact of these cost reductions on the cost of producing H2 will depend on the specific system where they are applied. Therefore, a Techno-Economic Analysis was completed using system cost as a variable, and showing how the NREL Current and Future system costs translate into H2 production cost.

Henrichsen, Lars↗

NASA NTRS1980

Cell module and fuel conditioner

Measurements of stack height changes with temperature and cell material characteristics were made. Stack 559 was assembled and components were fabricated for 560, 561, and 562. Stack 425 was transferred from the parallel DOE program and installed in the OS/IES simulation loop for mechanical and electrical testing. Construction and preliminary checkout of the 2 kW test facility was completed and design and procurement of the 8 kW test facility was initiated. The fuel conditioning subsystem design continued to evolve and the state points for the current design were calculated at full and part load conditions. Steam reforming catalyst activity tests were essentially completed and aging tests and CO shift converter tests were initiated.

Hoover, D. Q., Jr.↗

NASA NTRS1982

Control technology development

The main objectives of the control technology development task are given in the slide below. The first is to develop control design techniques based on flexible structural models, rather than simple rigid-body models. Since large space structures are distributed parameter systems, a new degree of freedom, that of sensor/actuator placement, may be exercised for improving control system performance. Another characteristic of large space structures is numerous oscillatory modes within the control bandwidth. Reduced-order controller design models must be developed which produce stable closed-loop systems when combined with the full-order system. Since the date of an actual large-space-structure flight is rapidly approaching, it is vitally important that theoretical developments are tested in actual hardware. Experimental verification is a vital counterpart of all current theoretical developments.

Schaechter, D. B.↗

NASA NTRS2003

An Improved Design for Air Removal from Aerospace Fluid Loop Coolant Systems

Aerospace applications with requirements for large capacity heat removal (launch vehicles, platforms, payloads, etc.) typically utilize a liquid coolant fluid as a transport media to increase efficiency and flexibility in the vehicle design. An issue with these systems however, is susceptibility to the presence of noncondensable gas (NCG) or air. The presence of air in a coolant loop can have numerous negative consequences, including loss of centrifugal pump prime, interference with sensor readings, inhibition of heat transfer, and coolant blockage to remote systems. Hardware ground processing to remove this air is also cumbersome and time consuming which continuously drives recurring costs. Current systems for maintaining the system free of air are tailored and have demonstrated only moderate success. An obvious solution to these problems is the development and advancement of a passive gas removal device, or gas trap, that would be installed in the flight cooling system simplifying the initial coolant fill procedure and also maintaining the system during operations. The proposed device would utilize commercially available membranes thus increasing reliability and reducing cost while also addressing both current and anticipated applications. In addition, it maintains current pressure drop, water loss, and size restrictions while increasing tolerance for pressure increases due to gas build-up in the trap.

Ritchie, Stephen M. C.↗

NASA NTRS2013

Neutron Characterization for Additive Manufacturing

Oak Ridge National Laboratory (ORNL) is leveraging decades of experience in neutron characterization of advanced materials together with resources such as the Spallation Neutron Source (SNS) and the High Flux Isotope Reactor (HFIR) shown in Fig. 1 to solve challenging problems in additive manufacturing (AM). Additive manufacturing, or three-dimensional (3-D) printing, is a rapidly maturing technology wherein components are built by selectively adding feedstock material at locations specified by a computer model. The majority of these technologies use thermally driven phase change mechanisms to convert the feedstock into functioning material. As the molten material cools and solidifies, the component is subjected to significant thermal gradients, generating significant internal stresses throughout the part (Fig. 2). As layers are added, inherent residual stresses cause warping and distortions that lead to geometrical differences between the final part and the original computer generated design. This effect also limits geometries that can be fabricated using AM, such as thin-walled, high-aspect- ratio, and overhanging structures. Distortion may be minimized by intelligent toolpath planning or strategic placement of support structures, but these approaches are not well understood and often "Edisonian" in nature. Residual stresses can also impact component performance during operation. For example, in a thermally cycled environment such as a high-pressure turbine engine, residual stresses can cause components to distort unpredictably. Different thermal treatments on as-fabricated AM components have been used to minimize residual stress, but components still retain a nonhomogeneous stress state and/or demonstrate a relaxation-derived geometric distortion. Industry, federal laboratory, and university collaboration is needed to address these challenges and enable the U.S. to compete in the global market. Work is currently being conducted on AM technologies at the ORNL Manufacturing Demonstration Facility (MDF) sponsored by the DOE's Advanced Manufacturing Office. The MDF is focusing on R&D of both metal and polymer AM pertaining to in-situ process monitoring and closed-loop controls; implementation of advanced materials in AM technologies; and demonstration, characterization, and optimization of next-generation technologies. ORNL is working directly with industry partners to leverage world-leading facilities in fields such as high performance computing, advanced materials characterization, and neutron sciences to solve fundamental challenges in advanced manufacturing. Specifically, MDF is leveraging two of the world's most advanced neutron facilities, the HFIR and SNS, to characterize additive manufactured components.

Watkins, Thomas↗

NASA NTRS2015

Automated Meta-Aircraft Operations for a More Efficient and Responsive Air Transportation System

A brief overview is given of the on-going NASA Automated Cooperative Trajectories project. Current status and upcoming work is previewed. The motivating factors and innovative aspects of ACT are discussed along with technical challenges and the expected system-level impacts if the project is successful. Preliminary results from the NASA G-III hardware in the loop simulation are included.

flight paths↗

NASA NTRS2015

Automated Meta-Aircraft Operations for a More Efficient and Responsive Air Transportation System

flight paths↗

NASA NTRS2017

The Human Performance Envelope: Past Research, Present Activities and Future Directions

Air traffic controllers (ATCOs) must maintain a consistently high level of human performance in order to maintain flight safety and efficiency. In current control environments, performance-influencing factors such as workload, fatigue and situation awareness can co-occur, and interact, to effect performance. However, multifactor influences and the association with performance are under-researched. This study utilized a high fidelity human in the loop enroute air traffic control simulation to investigate the relationship between workload, situation awareness and ATCO performance. The study aimed to replicate and extend Edwards, Sharples, Wilson and Kirwans (2012) previous study and confirm multifactor interactions with a participant sample of ex-controllers. The study also aimed to extend Edwards et als previous research by comparing multifactor relationships across 4 automation conditions. Results suggest that workload and SA may interact to produce a cumulative impact on controller performance, although the effect of the interaction on performance may be dependent on the context and amount of automation present. Findings have implications for human-automation teaming in air traffic control, and the potential prediction and support of ATCO performance.

human performance envelope↗

NASA NTRS2020

Tactical Separation and Safety Alerting System for Terminal Airspace

Provision of tactical alerts to aid air traffic controllers in providing separation assurance in terminal airspace is hindered by the complexity of the airspace, its operations, and flight procedures. A prototype automation system is studied that provides controllers with both separation and safety alerts based on or derived from the separation standard for terminal airspace. The system models flight trajectories heuristically, with use of merged intent information from readily available sources: area navigation departure procedures, flight-plan routes, and arrival nominal interior routes used in terminal automation systems. Flight vertical intent is modeled according to standard procedural restrictions except when superseded by controller-issued altitude clearances. Importantly, flight trajectories are modeled for all aircraft, including those conducting visual approaches. New safety-alert thresholds for aircraft conducting visual approaches are studied. Performance of the system is evaluated through fast-time playback of recorded air traffic data from high-fidelity Human-In-The-Loop simulations and real-world operations in two Terminal Radar Approach Control facilities. The prototype system is found to produce a false-alert rate of 8% for separation alerts. The number and validity of safety alerts are studied by comparing with the current Conflict Alert system, showing that the false alerts of Conflict Alert are at 85% and they are avoided in the prototype system.

Air Traffic Management↗

NASA NTRS2009

Exploration Life Support Technology Development for Lunar Missions

Exploration Life Support (ELS) is one of NASA's Exploration Technology Development Projects. ELS plans, coordinates and implements the development of new life support technologies for human exploration missions as outlined in NASA's Vision for Space Exploration. ELS technology development currently supports three major projects of the Constellation Program - the Orion Crew Exploration Vehicle (CEV), the Altair Lunar Lander and Lunar Surface Systems. ELS content includes Air Revitalization Systems (ARS), Water Recovery Systems (WRS), Waste Management Systems (WMS), Habitation Engineering, Systems Integration, Modeling and Analysis (SIMA), and Validation and Testing. The primary goal of the ELS project is to provide different technology options to Constellation which fill gaps or provide substantial improvements over the state-of-the-art in life support systems. Since the Constellation missions are so challenging, mass, power, and volume must be reduced from Space Shuttle and Space Station technologies. Systems engineering analysis also optimizes the overall architecture by considering all interfaces with the life support system and potential for reduction or reuse of resources. For long duration missions, technologies which aid in closure of air and water loops with increased reliability are essential as well as techniques to minimize or deal with waste. The ELS project utilizes in-house efforts at five NASA centers, aerospace industry contracts, Small Business Innovative Research contracts and other means to develop advanced life support technologies. Testing, analysis and reduced gravity flight experiments are also conducted at the NASA field centers. This paper gives a current status of technologies under development by ELS and relates them to the Constellation customers who will eventually use them.

Ewert, Michael K.↗

NASA NTRS2004

Development of a Crosslink Channel Simulator

Distributed Spacecraft missions are an integral part of current and future plans for NASA and other space agencies. Many of these multi-vehicle missions involve utilizing the array of spacecraft as a single, instrument requiring communication via crosslinks to achieve mission goals. NASA s Goddard Space Flight Center (GSFC) is developing the Formation Flying Test Bed (FFTB) to provide a hardware-in-the-loop simulation environment to support mission concept development and system trades with a primary focus on Guidance, Navigation, and Control (GN&C) challenges associated with spacecraft flying. The goal of the FFTB is to reduce mission risk by assisting in mission planning and analysis, provide a technology development platform that allows algorithms to be developed for mission functions such as precision formation navigation and control and time synchronization. The FFTB will provide a medium in which the various crosslink transponders being used in multi-vehicle missions can be integrated for development and test; an integral part of the FFTB is the Crosslink Channel Simulator (CCS). The CCS is placed into the communications channel between the crosslinks under test, and is used to simulate on-mission effects to the communications channel such as vehicle maneuvers, relative vehicle motion, or antenna misalignment. The CCS is based on the Starlight software programmable platform developed at General Dynamics Decision Systems and provides the CCS with the ability to be modified on the fly to adapt to new crosslink formats or mission parameters. This paper briefly describes the Formation Flying Test Bed and its potential uses. It then provides details on the current and future development of the Crosslink Channel Simulator and its capabilities.

Hunt, Chris↗

DOE OSTI2023

Power Hardware-in-the-Loop Interfaces for Inverter-Based Microgrid Experiments Including Transitions: Preprint

Microgrids continue to proliferate, particularly those that rely on inverter-based resources as the microgrid's voltage and frequency leader. Hardware-in-the-loop (HIL) simulations can de-risk microgrid deployments, and therefore we need power-hardware-in-the-loop (PHIL) interfaces for grid-forming (GFM) inverters to enable simulations of seamless transitions between islanded and grid-connected operation. Such microgrid interfaces are particularly challenging to model when the inverters need to switch modes, i.e., between grid-following (GFL) and GFM as the microgrid transitions between grid-connected and islanded operation. This paper presents two PHIL interfaces for such microgrids and the preliminary experimental results: One interface is suitable for those who have access to a power amplifier that can operate as a controllable current source, and the other is for those who need a solution that uses a voltage-mode power amplifier.

battery energy storage system↗

NASA NTRS2009

Dynamic Self-Locking of an OEO Containing a VCSEL

A method of dynamic self-locking has been demonstrated to be effective as a means of stabilizing the wavelength of light emitted by a vertical-cavity surface-emitting laser (VCSEL) that is an active element in the frequency-control loop of an optoelectronic oscillator (OEO) designed to implement an atomic clock based on an electromagnetically- induced-transparency (EIT) resonance. This scheme can be considered an alternative to the one described in Optical Injection Locking of a VCSEL in an OEO (NPO-43454), NASA Tech Briefs, Vol. 33, No. 7 (July 2009), page 33. Both schemes are expected to enable the development of small, low-power, high-stability atomic clocks that would be suitable for use in applications involving precise navigation and/or communication. To recapitulate from the cited prior article: In one essential aspect of operation of an OEO of the type described above, a microwave modulation signal is coupled into the VCSEL. Heretofore, it has been well known that the wavelength of light emitted by a VCSEL depends on its temperature and drive current, necessitating thorough stabilization of these operational parameters. Recently, it was discovered that the wavelength also depends on the microwave power coupled into the VCSEL. This concludes the background information. From the perspective that led to the conception of the optical injection-locking scheme described in the cited prior article, the variation of the VCSEL wavelength with the microwave power circulating in the frequency-control loop is regarded as a disadvantage and optical injection locking is a solution of the problem of stabilizing the wavelength in the presence of uncontrolled fluctuations in the microwave power. The present scheme for dynamic self-locking emerges from a different perspective, in which the dependence of VCSEL wavelength on microwave power is regarded as an advantageous phenomenon that can be exploited as a means of controlling the wavelength. The figure schematically depicts an atomic-clock OEO of the type in question, wherein (1) the light from the VCSEL is used to excite an EIT resonance in selected atoms in a gas cell (e.g., 87Rb atoms in a low-pressure mixture of Ar and Ne) and (2) the power supplied to the VCSEL is modulated by a microwave signal that includes components at beat frequencies among the VCSEL wavelength and modulation sidebands. As the VCSEL wavelength changes, it moves closer to or farther from a nearby absorption spectral line, and the optical power transmitted through the cell (and thus the loop gain) changes accordingly. A change in the loop gain causes a change in the microwave power and, thus, in the VCSEL wavelength. It is possible to choose a set of design and operational parameters (most importantly, the electronic part of the loop gain) such that the OEO stabilizes itself in the sense that an increase in circulating microwave power causes the VCSEL wavelength to change in a direction that results in an increase in optical absorption and thus a decrease in circulating microwave power. Typically, such an appropriate choice of operational parameters involves setting the nominal VCSEL wavelength to a point on the shorter-wavelength wing of an absorption spectral line.

Strekalov, Dmitry↗