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At least 1,369 records · Page 76

Modernizing NASA’s Space Flight Safety and Mission Success (S&MS) Assurance Framework In Line With Evolving Acquisition Strategies and Systems Engineering Practices

This paper presents the objectives-driven, case-based safety and mission success (S&MS) assurance framework being developed by the NASA Office of Safety and Mission Assurance (OSMA), including its motivations and its implementation via a S&MS Assurance Standard that is under development, supplemented by supporting standards including an S&MS Analysis Management Standard that is also under development. A need to evolve NASA’s S&MS assurance framework has emerged in recent years, resulting from the need to accommodate new acquisition models; the need to accommodate evolving systems engineering (SE) practices; the need to stipulate acceptable levels of S&MS risk; the need for improved integration of S&MS into SE; and the need for clearer risk acceptance accountability. The objectives-driven, case-based S&MS assurance framework proposed here is responsive to that need. Its key features include: • The establishment, by NASA Acquirers, of fundamental S&MS performance objectives that define limits of acceptability for the likelihoods that mission technical objectives will be accomplished and that people, assets, and environments put at risk by the mission will not be adversely affected; • The development and approval of Providers’ S&MS plans for meeting Acquirers’ S&MS performance objectives, including commitments to support Acquirer audit, investigation, and reporting needs; • The development, by Providers, of S&MS assurance cases that argue, supported by evidence, that the Provider has met, or is on track to meeting, the fundamental S&MS objectives; • The evaluation, throughout the program/project life cycle, of Provider S&MS assurance cases as the primary S&MS-related technical basis for Acquirer risk acceptance and the granting to the Provider of authority to proceed through the program/project life cycle. This proposed S&MS assurance framework is notable for its lack of prescription of traditional S&MS requirements and strategies such as defined failure tolerances, margins, or analysis requirements. Instead, Providers are given latitude to propose their own strategies for meeting the fundamental S&MS performance objectives, subject to independent review and Acquirer approval. The result is a framework for S&MS assurance that is at once both rigorous and flexible.

Assurance Case↗

Feasibilities of a Coal-Biomass to Liquids Plant in Southern West Virginia

This project has generated comprehensive and realistic results of feasibilities for a coal-biomass to liquids (CBTL) plant in southern West Virginia; and evaluated the sensitivity of the analyses to various anticipated scenarios and parametric uncertainties. Specifically the project has addressed economic feasibility, technical feasibility, market feasibility, and financial feasibility. In the economic feasibility study, a multi-objective siting model was developed and was then used to identify and rank the suitable facility sites. Spatial models were also developed to assess the biomass and coal feedstock availabilities and economics. Environmental impact analysis was conducted mainly to assess life cycle analysis and greenhouse gas emission. Uncertainty and sensitivity analysis were also investigated in this study. Sensitivity analyses on required selling price (RSP) and greenhouse gas (GHG) emissions of CBTL fuels were conducted according to feedstock availability and price, biomass to coal mix ratio, conversion rate, internal rate of return (IRR), capital cost, operational and maintenance cost. The study of siting and capacity showed that feedstock mixed ratio limited the CBTL production. The price of coal had a more dominant effect on RSP than that of biomass. Different mix ratios in the feedstock and conversion rates led to RSP ranging from $104.3 - $157.9/bbl. LCA results indicated that GHG emissions ranged from 80.62 kg CO 2 eq to 101.46 kg CO2 eq/1,000 MJ of liquid fuel at various biomass to coal mix ratios and conversion rates if carbon capture and storage (CCS) was applied. Most of water and fossil energy were consumed in conversion process. Compared to petroleum-derived-liquid fuels, the reduction in GHG emissions could be between -2.7% and 16.2% with CBTL substitution. As for the technical study, three approaches of coal and biomass to liquids, direct, indirect and hybrid, were considered in the analysis. The process models including conceptual design, process modeling and process validation were developed and validated for different cases. Equipment design and capital costs were investigated on capital coast estimation and economical model validation. Material and energy balances and techno-economic analysis on base case were conducted for evaluation of projects. Also, sensitives studies of direct and indirect approaches were both used to evaluate the CBTL plant economic performance. In this study, techno-economic analysis were conducted in Aspen Process Economic Analyzer (APEA) environment for indirect, direct, and hybrid CBTL plants with CCS based on high fidelity process models developed in Aspen Plus and Excel. The process thermal efficiency ranges from 45% to 67%. The break-even oil price ranges from $86.1 to $100.6 per barrel for small scale (10000 bbl/day) CBTL plants and from $65.3 to $80.5 per barrel for large scale (50000 bbl/day) CBTL plants. Increasing biomass/coal ratio from 8/92 to 20/80 would increase the break-even oil price of indirect CBTL plant by $3/bbl and decrease the break-even oil price of direct CBTL plant by about $1/bbl. The order of carbon capture penalty is direct > indirect > hybrid. The order of capital investment is hybrid (with or without shale gas utilization) > direct (without shale gas utilization) > indirect > direct (with shale gas utilization). The order of thermal efficiency is direct > hybrid > indirect. The order of break-even oil price is hybrid (without shale gas utilization) > direct (without shale gas utilization) > hybrid (with shale gas utilization) > indirect > direct (with shale gas utilization).

01 COAL, LIGNITE, AND PEAT↗

Advancing catalytic fast pyrolysis through integrated multiscale modeling and experimentation: Challenges, progress, and perspectives

Catalytic fast pyrolysis (CFP) is a conversion process that integrates rapid thermochemical depolymerization of solid feedstocks with catalytic transformation to yield small molecules for fuel and chemical products. This process is well-suited for the conversion of nonfossil feedstocks such as biomass and waste plastics, and thereby holds great potential for the production of renewable commodities. In spite of many technological developments in various aspects of CFP achieved over decades of research, this technology has yet to attain commercial success for the production of fuels and chemicals from renewable feedstocks. Effective CFP processes require careful coordination of chemical and physical phenomena that span very large length and time scales. A broad spectrum of scientific progress in both pyrolysis and catalytic upgrading has provided the foundation for successful deployment of CFP, although additional progress in process-scale integration is yet required for commercial realization. Modeling and simulation tools provide an important framework wherein the CFP technologies by be better understood and evaluated from a holistic perspective. Here we provide a detailed description of the multiscale phenomena underlying CFP, describe challenges and associated technical progress, and suggest strategies for an integrated approach to advance this technology toward commercialization.

09 BIOMASS FUELS↗

Status of the International Criticality Safety Benchmark Evaluation Project

The International Criticality Safety Benchmark Evaluation Project (ICSBEP) has continued its work generating evaluations of new and historical criticality benchmark experiments since the last update to the nuclear criticality safety community at the 11th International Conference on Nuclear Criticality Safety (ICNC 2019) in Paris, France. Three additional versions of the ICSBEP Handbook have been published since that update, and the Technical Review Group (TRG) held two in-person (in 2019 and 2023) and three virtual (2020 and 2021) meetings to review and approve additional benchmarks. The 2019 edition of the ICSBEP Handbook included five new evaluations with 79 new configurations, the 2020 version of the ICSBEP Handbook contained five new evaluations totaling 76 new configurations, and the 2021 version of the ICSBEP handbook contained five new evaluations with a total of 57 different configurations. The ICSBEP TRG met in October and December 2021, to review benchmarks for potential inclusion in the 2022 ICSBEP Handbook, with seven evaluations receiving provisional approval pending resolution of review group comments. Final comment resolution for some of these evaluations is currently underway and handbook publication should be completed soon. The ICSBEP TRG met again in person in April 2023 to review benchmarks for the 2023 ICSBEP Handbook, provisionally approving 7 new evaluations. The ICSBEP continues to deliver high-quality, peer reviewed evaluations of experiments relevant to the nuclear criticality safety community.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

System Configuration Evaluation for Process Settling of Hanford Waste Solid Particles

Direct Feed High-Level Waste (DFHLW) is a potential flowsheet operations approach to initiating high-level waste (HLW) vitrification prior to completion of the Hanford Waste Treatment and Immobilization Plant (WTP) Pretreatment Facility. A settle/decant process has been proposed to concentrate solids prior to delivery to the WTP HLW Facility during DFHLW operations, wherein the solids in a settled layer would be remixed with the supernatant liquid remaining after decanting operations to provide the feed at required solids concentrations. Settling would be used in lieu of purpose-built filtration or other solids separation equipment. Pacific Northwest National Laboratory (PNNL) is providing baseline technical support to the Washington River Protection Solutions (WRPS) Flowsheet Integration group. To support planning for DFHLW, WRPS previously requested that PNNL evaluate the current data set available to predict the time needed for HLW solids to settle and the solids concentration and strength of that settled layer, to identify gaps in the understanding and predictive capability of HLW solids waste settling times, and to provide scoping estimates of the potential settling times. Eight technical gaps were identified for predicting settling times and characteristics of the formed sediment layers. In addition to the data gaps, an overarching observation was made that there is significant variation in behavior of settling rate and settled layer data. The settling time required to concentrate solids via a settle/decant process was determined from the limited data to have a difference of potentially more than a factor of 5,000 in the estimated settling times, varying from 0.2 to 1,060 days for example depending on process vessel depth and final sediment solids concentration. In contrast, successful processes of liquid-forward output streams resulting from in-tank settling and decanting forward liquid have been reported for operations conducted at the Hanford Site. The purpose of this current report is to further support DFHLW planning by evaluating double-shell tank (DST) and alternate vessel equipment and operational configurations to enable optimization of the settle/decant process to concentrate solids. Hanford waste processing behavior specific to liquid feed availability following a slurry transfer in a DST is summarized, including process stream characteristics and process equipment configurations. The performance of DST process equipment configurations is evaluated for possible improvements using computational fluid dynamics (CFD) and simple analytical models. Potential new vessel design(s) specific to enabling effective settle/decant processes, and cursory summary of other separate and inline solids separations processes, are also provided. The CFD results indicated that improvement in outflow solids concentration was promoted by a reduction in the slurry flow rate, angling the distributor nozzles downward, and lifting the transfer pump. The solid-liquid analysis evaluating particle trajectory confirmed that the potential for particle ingestion (in the transfer pump) was decreased with increased radial separation between the inlet and outlet (transfer pump inlet), decreased inlet flow, and decreased liquid density and viscosity for a neutrally buoyant inlet flow. An assessment was also made of the potential for inflow configuration changes to result in the discrete mounding or piling of solids within the tank. Based on the characterization of the settled waste to date, HLW sediments will be unlikely to sustain a substantial angle of repose to facilitate significant variations in the elevation of the settled solids.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Milestone 2.7: Evaluation of Techniques for the Measurement of Molecular Hydrogen Gas in Helium Matrices

Published data by Task 2 (Oxyhydroxide Layer Radiolytic Gas Generation Resolution) for Technical Considerations and Challenges for Extended (>50 yrs) Dry Storage of Aluminum Cladded Spent Nuclear Fuel (ASNF), demonstrated that radiolytic molecular hydrogen (H2) production from gamma irradiated aluminum alloy 1100 (Al-1100) coupons exhibited significant dependence on backfill gaseous environment conditions: air, due to the presence of oxygen, completely inhibited H2 production; nitrogen promoted H2 production; and argon yielded more H2 than nitrogen environments. The concern here is that helium has been proposed as the backfill gas for extended storage and is more inert than argon, which may translate into significantly more H2 production than current Task 3 argon-based models predict. However, the measurement of H2 in helium media was not possible using the previously establish gas chromatography (GC) flame ionization detector, due to similarities in thermal conductivity. This milestone was initiated to evaluate an alternative GC approach that employed a mercuric oxide (HgO) reduction gas detector (RGD). Using the HgO RGD setup, H2 was successfully calibrated in the presence of a helium carrier gas, and then subsequently measured in control and irradiated crush-tube sample vials, consistent with previous sample measurements. Overall, the HgO RGD approach was found to be sufficient for future helium environment irradiations.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

Report to the administrator by the NASA Aerospace Safety Advisory Panel on the Skylab program. Volume 1: Summary report

Contractor and NASA technical management for the development and manufacture of the Skylab modules is reviewed with emphasis on the following management controls: configuration and interface management; vendor control; and quality control of workmanship. A review of the modified two-stage Saturn V launch vehicle which focused on modifications to accommodate the Skylab payload; resolution of prior flight anomalies; and changes in personnel and management systems is presented along with an evaluation of the possible age-life and storage problems for the Saturn 1-B launch vehicle. The NASA program management's visibility and control of contractor operations, systems engineering and integration, the review process for the evaluation of design and flight hardware, and the planning process for mission operations are investigated. It is concluded that the technical management system for development and fabrication of the modules, spacecraft, and launch vehicles, the process of design and hardware acceptance reviews, and the risk assessment activities are satisfactory. It is indicated that checkout activity, integrated testing, and preparations for and execution of mission operation require management attention.

Source record↗

An Introduction to Grid Services: Concepts, Technical Requirements, and Provision from Wind

As the role of wind energy grows in the U.S. power grid, there is increased interest and requirements for it to provide 'essential reliability' services (historically often referred to as 'ancillary' services). These services are critical to maintaining the reliability and stability of the grid, and historically were provided by large 'synchronous' generators, mainly fossil-fueled and hydroelectric generators. To help evaluate the potential role of wind in providing these services, this report provides an overview of services provided to the grid, including their technical requirements, quantities currently procured, and some estimates of costs. The report also summarizes the technical and regulatory issues around wind providing these services.

17 WIND ENERGY↗

An Introduction to Grid Services: Concepts, Technical Requirements, and Provision from Wind

As the role of wind energy grows in the U.S. power grid, there is increased interest and requirements for it to provide 'essential reliability' services (historically often referred to as 'ancillary' services). These services are critical to maintaining the reliability and stability of the grid, and historically were provided by large 'synchronous' generators, mainly fossil-fueled and hydroelectric generators. To help evaluate the potential role of wind in providing these services, this report provides an overview of services provided to the grid, including their technical requirements, quantities currently procured, and some estimates of costs. The report also summarizes the technical and regulatory issues around wind providing these services.

17 WIND ENERGY↗

Analysis and Design for Sustainable Circularity of Barrier Films Used in Sheet Molding Composites Production

Sheet molding composites (SMC) are thermoset based molding compounds with a global market size of USD 2.1 billion in 2020. SMC is usually processed with multilayer barrier/carrier films to prevent emissions from volatile organic compounds (VOC). The plastic barriers are separated from SMC after the curing process and discarded. To illustrate the high consumption volume of SMC barrier/carrier films, Kohler Co., a company which uses SMC in their bath and showering product lines, alone generates over 1M lb/year of SMC barrier/carrier film waste. Therefore, high amount of SMC barrier/carrier film plastic waste creates a great opportunity for reusing, recycling, or valorization at its end of life. This can be achieved through transition from a linear to a circular supply chain design. However, this transition will not be feasible without overcoming the technical and economic barriers. This project aims to tackle this by making the film circular. Different end of life alternatives will be evaluated experimentally. The reusability of the film will be studied through applying different mechanical and solvent cleaning techniques. The operability concerns regarding the utilization of the cleaned film for long run operations will be addressed by thermally stitching the film. Pelletizing of the cleaned film will also be investigated as a viable technique for recycling or downcycling of the film as molded products. In addition to technical barriers, designing a sustainable circular supply chain for SMC carrier film products requires uncovering the collaboration opportunities between suppliers and users at different stages of the value chain to expand its use to other products. These opportunities will be investigated by finding companies willing to buy or treat the plastic film waste. Finally, the economic viability and environmental impacts of these circular design alternatives will be evaluated through techno-economic assessment (TEA) and life cycle analysis (LCA). Techno-economic and life cycle inventory data for various pathways will also be made available as one of the main outcomes of this project. Preliminary LCA results indicate that the current SMC film supply chain (base case) emits 5.81 tonne CO2 eq. and consumes 104 GJ energy per tonne of SMC film. It is estimated that alternative circular pathways result in 14-20% less CO2 emissions and 34-44% reduction in embodied energy. This project will develop a tool to analyze the circularity and sustainability of hundreds of combinations of alternatives in different life cycle stages. Users of this tool will be able to choose the best combination among these alternatives with respect to the selected economic, environmental and circularity objectives.

circular economy↗

Nano Filters for Selective Metal Capture (CRADA Final Report)

As part of the Cyclotron Road program, Sunchem investigated novel nanoporous materials and their metal extraction performance in both batch and dynamic continuous flow operations. The proposed project developed novel nanoporous materials for selective metal extraction from complex industrial mixtures. The technical objectives were to synthesize and characterize the nanoporous materials, structure the nanoporous materials with binders along with structuring techniques and evaluate its performance in both a batch and dynamic continuous flow operation. The nanoporous material was structured through a disc granulation method to obtain particles in the size range of 250 to 500 micron diameter. This structured material was packed into a continuous flow column which achieved up to 48 wt% of gold capture. This work aimed to address the key technical risk of the materials’ capability to be employed in an industrial operation with competitive performance compared to other adsorbents.

36 MATERIALS SCIENCE↗

Basis of Knowledge for Oxidizing Chemicals in TRU Waste - 18654

A new Waste Isolation Pilot Plant (WIPP) document for implementing new requirements in the WIPP Waste Acceptance Criteria (WAC) titled Basis of Knowledge for Evaluating Oxidizing Chemicals in the TRU waste was issued in July, 2017 and has now been implemented on several waste streams. The February 14, 2014, airborne radiation release in Room 7 of the WIPP underground disposal unit 7 was caused by an exothermic chemical reaction of nitrate oxidizing chemicals and organic materials in a single 55-gallon container. That event exposed hazards not previously evaluated in the WIPP safety basis. A new WIPP Documented Safety Analysis (DSA), Revision 5b, was developed that addressed potential hazards related to the airborne radiation release and evaluated and addressed new fire hazard scenarios. The revised hazards analysis within the DSA specifically included potential chemical exothermic reactions in waste containers and propagating fires. Compliance with WAC was credited as initial conditions to the hazards analysis, and Chapter 18 was added making the WIPP WAC compliance program a safety management program within the DSA. The WIPP DSA, Revision 5b, Chapter 18, and the WIPP WAC require the use of this document when performing the enhanced acceptable knowledge (AK) process on transuranic (TRU) waste determined to contain oxidizing chemicals. The WIPP WAC was revised to address the conditions and requirements of DSA Revision 5b. The use of this Basis of Knowledge (BoK) by WIPP Certified Programs is specified in the WIPP WAC, Appendix H, Enhanced Acceptable Knowledge. This document establishes criteria that must be used by the WIPP Certified Programs to evaluate TRU waste containing one or more oxidizing chemicals to determine acceptability at the WIPP as-is and to identify when additional evaluation or treatment is required. This BoK also includes options and requirements to be used by TRU waste sites when further evaluation, testing, and/or treatment are required. The U.S. Department of Energy (DOE) Carlsbad Field Office (CBFO) will review requests, plans, and technical justifications and provide written decisions prior to implementation by the TRU waste sites. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Milestone 2.8: Preliminary Radiolytic Gas Generation Measurements from Helium-Backfilled Samples

The Department of Energy (DOE) is currently managing nearly 13 metric tons of aluminum-clad spent nuclear fuel (ASNF) with the intention of extended (> 50 years) dry storage in helium-backfilled canisters. Due to in-reactor and cooling pond conditions, oxyhydroxide corrosion layers have formed on the surface of the ASNF elements. These corrosion layers are susceptible to radiolysis and the formation of molecular hydrogen gas (H 2 ) due to the fuel’s inherent radiation field. Consequently, a rigorous evaluation of the effect of helium gas on radiolytic H 2 production is necessary to support the Technical Considerations and Challenges for Extended (> 50 yrs) Dry Storage of ASNF program, especially as previous Task 2 - Oxyhydroxide Layer Radiolytic Gas Generation Resolution work demonstrated a significant effect of gas composition on the radiolytic yield (G-value) of H 2 . Here we report preliminary G-values for the radiolytic formation of H 2 from the gamma irradiation of pre-corroded aluminum alloy 1100 coupons flame sealed in helium environments. Irradiations yielded G(H 2 ) values of (5.1 ± 0.5) x 10 –4 and (9.4 ± 0.9) x 10 –4 µmol J –1 for pristine coupons, and (10.1 ± 0.4) x 10 –4 and (15.1 ± 1.2) x 10 –4 µmol J –1 for pre-corroded coupons for 0% and 50% relative humidity, respectively. These helium environment G(H 2 ) values are between 28% and 58% higher than previously reported values for argon environments. This enhancement is attributed to the significant difference in first ionization energy between helium (24.59 eV) and argon (15.76) facilitating additional processes, e.g., Penning ionization. These new preliminary helium environment G(H 2 ) values will be employed by Task 3 - Sealed and Vented System Episodic Breathing and Gas Generation Prediction to model the effect of radiolytic H 2 accumulation in helium environments to evaluate the practicality of the extended storage standard canister design.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

SU-F-T-237: The Imaging and Radiation Oncology Core (IROC) Cooperatives Activities Supporting the NCI’s National Clinical Trial Network

Purpose: The Imaging and Radiation Oncology Core (IROC) Cooperative has been active for the past two years supporting the National Clinical Trial Network and the details of that support are reported. Methods: There are six QA centers (Houston, Ohio, Philadelphia-RT, Philadelphia-DI, Rhode Island, St. Louis) providing an integrated RT and DI quality control program in support of the NCI’s clinical trials. The QA Center’s efforts are focused on assuring high quality data for clinical trials designed to improve the clinical outcomes for cancer patients worldwide. This program is administered through five core services: site qualification, trial design support, credentialing, data management, and case review. Results: IROC currently provides core support for 172 NCTN trials with RT, DI and RT/DI components. Many of these trials were legacy trial from the previous cooperative group program. IROC monitors nearly 1800 RT photon and 20 proton institutions. Over 28,000 beams outputs were monitored with 8% of the sites requiring repeat audits due to beam out of criteria. As part of credentialing, 950 QA phantoms have been irradiated, 515 imaging modalities evaluated and almost 4000 credentialing letters have been issued. In just year 2, 5290 RT and 4934 DI patient datasets were received (many using TRIAD) by IROC QA Centers to be prepared for review. During the past 2 years, a total of 6300 RT cases and 19,000 DI image sets were reviewed by IROC technical staff. To date, IROC has published 36 manuscripts. Conclusion: The QA services provided by IROC are numerous and are continually being evaluated for effectiveness, harmonized across all NCTN Groups and administered in an efficient and timely manner to enhance accurate and per protocol trial data submission. These efforts increase each NCTN Group’s ability to derive meaningful outcomes from their clinical trials. This work was supported by DHHS NIH grant 5U24CA180803.

60 APPLIED LIFE SCIENCES↗

Evaluation of Improvements in Storage Efficiencies, Containment, Assurance, CO 2 Plume Movement, and Verification of Storage Technologies

This report summarizes some of the evolving improvements in key technical skills that are developing to support a large-scale commercial application of CCS as well as support rapidly increasing interest in carbon negative technologies. It does not attempt to review relatively well-known processes and procedures that are familiar to many CCS experts; rather focuses on novel concepts that have the potential to provide breakthroughs and add high benefit as projects evolve. Some elements described are in development or not yet proven ideas for which we provide an expression of status of confidence at the time of writing. Topics covered are evaluation of improvements in storage efficiency estimation, containment assurance methods, CO 2 plume movement and pressure prediction, and monitoring and verification of storage methods.

54 ENVIRONMENTAL SCIENCES↗

Evaluation of the MICAST #2-12 AI-7wt%Si Sample Directionally Solidified Aboard the International Space Station

The US team of the European led "MIcrostructure Formation in CASTing of Technical Alloys under Diffusive and Magnetically Controlled Convective Conditions" (MICAST) program recently received a third Aluminum - 7wt% silicon alloy that was processed in the microgravity environment aboard the International Space Station. The sample, designated MICAST#2-12, was directionally solidified in the Solidification with Quench Furnace (SQF) at a constant rate of 40micometers/s through an imposed temperature gradient of 31K/cm. Procedures taken to evaluate the state of the sample prior to sectioning for metallographic analysis are reviewed and rational for measuring the microstructural constituents, in particular the primary dendrite arm spacing (Lambda (sub1)), is given. The data are presented, put in context with the earlier samples, and evaluated in view of a relevant theoretical model.

Tewari, Surendra N.↗

Results of ISO/TS 6336-22 Evaluating Full Contact Zone

ISO/TS 6336-22 (Calculation of load capacity of spur and helical gears - Part 22: Calculation of micropitting load capacity) is the ISO technical specification containing a proposal for calculations of the risk of micropitting in gear sets. Micropitting is a Hertzian fatigue phenomenon that appears as ultra-fine cracking and pitting on the flanks of gear teeth. Since progressive micropitting can lead to macropitting and flank damage, critical applications such as wind turbines, marine drives, and high-speed gear drives seek to accurately predict whether their designs are susceptible to this damage. ISO/TS 6336-22 assesses micropitting risk through a safety factor which is calculated as the minimum specific film thickness in the contact zone divided by a permissible specific film thickness. In the previous paper, the calculations were performed using the simplified method (Method B) that evaluates points on the path of contact. This was done for three gear sets that experienced micropitting in operation. The minimum specific film thickness for the two field cases was very high, which indicates that the gears were operating in the full elastohydrodynamic lubrication (EHL) regime. A more accurate calculation for these cases (Method A) calculates the specific film thickness across the entire contact zone. This paper applies this Method to the case study from the previous paper. The results are compared to micropitting observed in operation. Results are also compared to the results of the previous paper. Conclusions are made regarding the accuracy of both Methods compared to the field cases and relative to each other.

ENGINEERING,WIND ENERGY↗