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Modular, Multifunction, Multiport and Medium Voltage Utility Scale SiC PV Inverter (Final Report)

This project is to develop and demonstrate a Modular, Multi-function, Multiport and Medium Voltage utility scale SiC solar inverter (M4 Inverter). The M4 Inverter is a next generation utility scale PV + storage inverter that can substantially reduce the levelized cost of energy (LCOE) while providing grid friendly ancillary services. Conventional utility scale solar inverters includes three parts, a megawatt rated solar inverter, a low frequency transformer (LFT) and a medium voltage switch gear. The proposed M4 Inverter directly converts the DC output of solar panels to medium voltage AC, eliminating the bulky and costly LFT. The M4 Inverter also has a DC port to interface with an additional energy storage device. This plus its bidirectional power flow capability, allows multiple functions in addition to PV maximum power tracking be achieved. These additional functionalities include but not limited to reactive power support, peak shaving, fast frequency regulation and synthetic inertia. Predicted LCOE reductions with these added functionalities, improved efficiency and longer lifetime time are more than 30% compared with the 2017 utility scale solar LCOE. A 1MVA SiC M4 Inverter was developed and tested at high power level. The project has also advanced the state of the art in controller hardware in the loop simulation capability. Power electronic innovations introduced in the M4 Inverter includes 1700V SiC MOSFET application in 1500V PV system, soft switching three-port power converters and modular converter architecture.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Advanced Stirling Convertor Control Unit Testing at NASA Glenn Research Center in the Radioisotope Power Systems System Integration Laboratory

Future NASA missions could include establishing Lunar or Martian base camps, exploring Jupiters moons and travelling beyond where generating power from sunlight may be limited. Radioisotope Power Systems (RPS) provide a dependable power source for missions where inadequate sunlight or operational requirements make other power systems impractical. Over the past decade, NASA Glenn Research Center (GRC) has been supporting the development of RPSs. The Advanced Stirling Radioisotope Generator (ASRG) utilized a pair of Advanced Stirling Convertors (ASC). While flight development of the ASRG has been cancelled, much of the technology and hardware continued development and testing to guide future activities. Specifically, a controller for the convertor(s) is an integral part of a Stirling-based RPS. For the ASRG design, the controller maintains stable operation of the convertors, regulates the alternating current produced by the linear alternator of the convertor, provides a specified direct current output voltage for the spacecraft, synchronizes the piston motion of the two convertors in order to minimize vibration as well as manage and maintain operation with a stable piston amplitude and hot end temperature. It not only provides power to the spacecraft but also must regulate convertor operation to avoid damage to internal components and maintain safe thermal conditions after fueling. Lockheed Martin Coherent Technologies has designed, developed and tested an Engineering Development Unit (EDU) Advanced Stirling Convertor Control Unit (ACU) to support this effort. GRC used the ACU EDU as part of its non-nuclear representation of a RPS which also consists of a pair of Dual Advanced Stirling Convertor Simulator (DASCS), and associated support equipment to perform a test in the Radioisotope Power Systems System Integration Laboratory (RSIL). The RSIL was designed and built to evaluate hardware utilizing RPS technology. The RSIL provides insight into the electrical interactions between as many as 3 radioisotope power generators, associated control strategies, and typical electric system loads. The first phase of testing included a DASCS which was developed by Johns Hopkins UniversityApplied Physics Laboratory and simulates the operation and electrical behavior of a pair of ASCs in real time via a combination of hardware and software. Testing included the following spacecraft electrical energy storage configurations: capacitive, battery, and supercapacitor. Testing of the DASCS and ACU in each energy storage configuration included simulation of a typical mission profile, and transient voltage and current data during load turn-on/turn-off. Testing for these devices also included the initiation of several system faults such as short circuits, electrical bus over-voltage, under-voltage and a dead bus recovery to restore normal power operations. The goal of this testing was to verify operation of the ACU(s) when connected to a spacecraft electrical bus.

Dugala, Gina M.↗

Advanced Stirling Convertor Control Unit Testing at NASA Glenn Research Center in the Radioisotope Power Systems System Integration Laboratory

Future NASA missions could include long-duration flyby, orbital, lander, or rover applications where generating power from sunlight may be limited. Radioisotope power systems (RPSs) provide a dependable power source for missions where inadequate sunlight or operational requirements make other power systems impractical. Over the past 16 years, NASA Glenn Research Center has been supporting the development of RPSs. The advanced Stirling radioisotope generator (ASRG) utilized a pair of advanced Stirling convertors (ASCs). Although flight development of the ASRG has been canceled, much of the technology and hardware continued development and testing to guide future activities. Specifically, a controller for the convertor(s) is an integral part of a Stirling-based RPS. For the ASRG design, the controller maintains stable operation of the convertors, regulates the alternating current produced by the linear alternator of the convertor, provides a specified direct-current output voltage for the spacecraft, and synchronizes the piston motion of the two convertors to minimize vibration as well as manage and maintain operation with a stable piston amplitude and hot-end temperature. It not only provides power to the spacecraft but also must regulate convertor operation to avoid damage to internal components and maintain safe thermal conditions after fueling. Lockheed Martin Coherent Technologies, Inc., has designed, developed, and tested an ASC control unit engineering development unit (ACU EDU) to support this effort. GRC used the ACU EDU as part of its nonnuclear representation of a RPS that also consists of a Dual advanced Stirling convertor simulator (DASCS), and associated support equipment to perform a test in the Radioisotope Power Systems System Integration Laboratory (RSIL). The RSIL was designed and built with flexibility to evaluate hardware utilizing RPS technology. The RSIL provides insight into the electrical interactions between as many as three radioisotope power generators, associated control strategies, and typical electric system loads. The first phase of testing included a DASCS that was developed by Johns Hopkins University Applied Physics Laboratory and simulates the operation and electrical behavior of a pair of ASCs in real time via a combination of hardware and software. Testing included the following spacecraft electrical energy storage configurations: capacitor, battery, and supercapacitor. Testing of the DASCS and ACU in each energy storage configuration included simulation of a typical mission profile and transient voltage and current data during load turnon and turnoff. Testing for these devices also included the initiation of several system faults such as short circuits, electrical bus overvoltage, undervoltage, and a "dead bus" recovery to restore normal power operations. The goal of this testing was to verify operation of the ACU(s) when connected to a spacecraft electrical bus. The results of these tests are presented here.

General↗

AOI 3 Life Modelling of Critical Steam Cycle Components in Coal-Fueled Power Plants

Microstructural damage accumulation models have been used to produce calibrated life estimation models for a DR22/P22 steel wye-block welds, and a Jethete stainless steel turbine blade (bucket). The calibrated life estimation models will aid the power plant operator in determining optimal maintenance and operation schedules based upon historical operational data as well as current, or future operation schemes. The impact of this project will enable existing coal-fueled power plants to operate safely for longer periods of time and at higher efficiencies, thereby reducing the economic and environmental impact of the existing coal power plant fleet. Testing, characterization, and modelling indicates that the operating life of P22 pipelines and their welds are dominated by fatigue damage mechanisms. Specifically, fatigue is of no concern in these materials when operating under realistic conditions manifesting in the main steam piping of coal-fueled power plants. However, if a low-temperature overload ever occurs during operation, fatigue will manifest as a damage mechanism of interest. Primary impact provided by the completion of this work is in the manifestation of a detailed ABAQUS solid model providing accurate boundary conditions to enable the prediction of operational stresses and strains. The completed plant solid model, in conjunction with the calibrated fatigue and creep life models provide definitive confirmation that creep is the dominant damage mechanism during operational conditions. Jethete life modelling has been completed by the manifestation of a material-specific, and temperature-specific, Kitagowa diagram. The Kitagowa diagram provides maintenance and operation decision making with scientifically-based go/no-go support based upon the crack-like features that have been identified by use of inspection.

01 COAL, LIGNITE, AND PEAT↗

Report on Year-4 of Water NSTF Matrix Testing: Facility Maintenance and Accident Testing

Under support from the Department of Energy (DOE) and the Office of Advanced Reactor Technologies (ART), a large-scale test facility has been constructed at Argonne National Laboratory to generate NQA-1 qualified validation data for passive decay heat removal systems in advanced reactors. The Natural convection Shutdown heat removal Test Facility (NSTF) reflects key features of a ½ scale, water-based, Reactor Cavity Cooling System (RCCS) and is intended to study the behavior, bound performance, and ultimately guide design decisions for passive decay heat removal systems for advanced reactors. In addition to the experimental activities detailed in this report, a supportive computational modeling effort is on-going which has been demonstrated to significantly strengthen the experimental program while also improving accuracy of the computer models. Together these create a mutually beneficial relationship integral to meeting the overall program objective of examining the heat removal performance of the RCCS concept. This report serves as a summary of maintenance and experimental activities during the program’s fourth year of water-based operation. A planned six-month maintenance period began in August 2021, during which major inspections, repairs, cleaning, and installation of new instrumentation and data acquisition hardware were conducted. Most significantly, two heaters that faulted during Year-3 were repaired, allowing the facility to resume use of the full heated section area and full range of available electric power. The remainder of the year consisted of eight months of test operations, during which the facility logged 211 hours of active heating across one bake-out (following the maintenance period) and seven matrix tests; five classifieds as Accepted per NQA-1, one as Trending, and one as Failed. Testing began by performing two repeat cases to confirm expected facility response and behavior during both single- and two-phase flow conditions, ensuring no changes were introduced during the maintenance period that might have altered the thermal-hydraulic characteristics of the facility. In continuation of the power parametric series initiated in previous years, a high-power test case was then performed examining heat removal performance at a decay heat load equivalent to 2.4 MWt, full-scale, a level exceeding maximum design targets. Additional testing then introduced various blockage scenarios along the network piping, examining the effects of partial and complete blockages of the flow paths on the system behavior and heat removal performance. A study of static boiling tests directed at understanding the geysering two-phase instability was also conducted. The loop was filled only to the bottom of the tank outlet, creating an open loop configuration that prevents any natural circulation flow from occurring, and the heaters were powered on until the facility reached saturation conditions. Following, a series of quasi-steady-state conditions were introduced by adjusting the inventory level in the adiabatic chimney piping at decreasingly lower elevations above the heated region. A strong correlation of geysering characteristics and loop level was observed, with flow and temperature excursions decreasing in intensity, but increasing in frequency, as the fill were reduced to lower elevations along the chimney piping. Once the level fell very low in the chimney, at points near the top of the heated section, the system reached a stable state of continuous boiling without any occurrence of geysering eruptions. A final significant testing accomplishment this year was successful completion of an “accident scenario” test, whose operating conditions were based on a prototypic decay heat curve provided by Framatome and scaled for the NSTF. This test began by establishing steady-state, single-phase “normal operation” conditions, before simulating an accident trip where the availability of active cooling systems was lost. Loop temperatures gradually increased until reaching saturation and subsequent two-phase boiling flow. Over the course of an extended operational period along the defined decay heat curve, steam boil-off caused gradual but continued depletion of liquid inventory until reaching a critically low level causing flow stagnation and cessation of natural circulation heat removal. At this point, after nearly 72 hours of continuous operation, a cold refill was performed to replenish the system inventory and allow the facility to re-establish closed loop natural circulation flow and return to a safe operational state.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Integrate Power Conversion Unit with MAGNET to Enable Integrated Microreactor Heat Transfer System Testing

Idaho National Laboratory obtained a closed, Brayton-cycle, power conversion unit (PCU) from Sandia National Laboratories. This PCU began as a commercially available, 30 kWe, C30, gas turbine from Capstone. The C30 was modified to use heat from an electric heater in a closed-loop system pressurized with nitrogen or dry air. INL has modified the unit further to integrate it with MAGNET and use heat from a microreactor test article.

42 - ENGINEERING↗

AC power system breadboard

The object of this program was to design, build, test, and deliver a high-frequency (20-kHz) Power System Breadboard which would electrically approximate a pair of dual redundant power channels of an IOC Space Station. This report describes that program, including the technical background, and discusses the results, showing that the major assumptions about the characteristics of this class of hardware (size, mass, efficiency, control, etc.) were substantially correct. This testbed equipment has been completed and delivered to LeRC, where it is operating as a part of the Space Station Power System Test Facility.

Wappes, Loran J.↗

Pressure distributions from high Reynolds number tests of a Boeing BAC 1 airfoil in the Langley 0.3-meter transonic cryogenic tunnel

A wind-tunnel investigation designed to test a Boeing advanced-technology airfoil from low to flight-equivalent Reynolds numbers has been completed in the Langley 0.3-Meter Transonic Cryogenic Tunnel. This investigation represents the first in a series of NASA/U.S. industry two-dimensional airfoil studies to be completed in the Advanced Technology Airfoil Test program. Test temperature was varied from ambient to about 100 K at pressures ranging from about 1.2 to 6.0 atm. Mach number was varied from about 0.40 to 0.80. These variables provided a Reynolds number (based on airfoil chord) range from 4.4 X 10 to the 6th power to 50.0 X 10 to the 6th power. All the test objectives were met. The pressure data are presented without analysis in plotted and tabulated formats for use in conjunction with the aerodynamic coefficient data published as NASA TM-81922. At the time of the test, these pressure data were considered proprietary and have only recently been made available by Boeing for general release. Data are included which demonstrate the effects of fixed transition. Also included are remarks on the model design, the model structural integrity, and the overall test experience.

Johnson, W. G., Jr.↗

ISRU Pilot Excavator Wheel Testing in Lunar Regolith Simulant

The ISRU Pilot Excavator, or IPEx, is a robotic excavator funded by NASA’s Space Technology Mission Directorate (STMD). The Concept of Operations for IPEx involves the robot driving on the lunar surface up to 70 km at a speed of up to 30 cm/s. As such, it is critical to the mission’s success to optimize the design of the wheels for performance in lunar conditions, specifically in lunar regolith. To achieve this, an array of tests was completed to observe the effects of various wheel design choices on the driving performance of the wheels in lunar regolith simulant. In order to facilitate testing, we designed a 12” dia. configurable wheel to allow for interchangeability between various wheel formations. Two types of wheel parts were designed to be swapped: cleats, which form the tread of the wheel; and grousers, which protrude from the treads. The test variables that we considered were as follows: square vs. round wheel shape, solid vs. perforated cleats, cleat spacing, grouser height, and grouser spacing. By combining different settings of each of these test variables, ten discrete wheel designs were created and tested. The configurable test wheels were mounted on the Regolith Advanced Surface Systems Operations Robot (RASSOR) developed at NASA’s Kennedy Space Center. In our experiments, the robot was driven at a controlled speed across a prepared surface of BP-1 lunar regolith simulant. Four types of tests were conducted: circle driving, straight driving, slope driving, and drawbar pull. The driving tests were chosen to mimic a variety of conditions in which IPEx may be expected to operate, and the drawbar pull test was chosen to provide a standard of comparison with existing wheel design literature. The circle and straight driving tests were each performed at different levels: for the circle driving test, the robot was driven at a constant linear speed and three different angular speeds, while for the straight driving test, the robot was driven at three different linear speeds. The data collected from these tests included the power usage from each of the wheels, measurements of the tread patterns left in the regolith surface, and the amount of slip the wheels experienced, which was calculated using data from an OptiTrack motion capture system. From the results of these experiments, we found that certain test variables were more significant than others in determining performance for each type of test, and no single wheel design clearly outperformed the others in all areas. The details of our findings will be discussed further in this paper. This data will be utilized to inform the design of the wheels for IPEx and can provide a basis for the design of wheels for future lunar terrain vehicles.

RASSOR↗

Automatic Detection of Electric Power Troubles (ADEPT)

ADEPT is an expert system that integrates knowledge from three different suppliers to offer an advanced fault-detection system, and is designed for two modes of operation: real-time fault isolation and simulated modeling. Real time fault isolation of components is accomplished on a power system breadboard through the Fault Isolation Expert System (FIES II) interface with a rule system developed in-house. Faults are quickly detected and displayed and the rules and chain of reasoning optionally provided on a Laser printer. This system consists of a simulated Space Station power module using direct-current power supplies for Solar arrays on three power busses. For tests of the system's ability to locate faults inserted via switches, loads are configured by an INTEL microcomputer and the Symbolics artificial intelligence development system. As these loads are resistive in nature, Ohm's Law is used as the basis for rules by which faults are located. The three-bus system can correct faults automatically where there is a surplus of power available on any of the three busses. Techniques developed and used can be applied readily to other control systems requiring rapid intelligent decisions. Simulated modelling, used for theoretical studies, is implemented using a modified version of Kennedy Space Center's KATE (Knowledge-Based Automatic Test Equipment), FIES II windowing, and an ADEPT knowledge base. A load scheduler and a fault recovery system are currently under development to support both modes of operation.

Wang, Caroline↗

Automatic Detection of Electric Power Troubles (ADEPT)

Automatic Detection of Electric Power Troubles (A DEPT) is an expert system that integrates knowledge from three different suppliers to offer an advanced fault-detection system. It is designed for two modes of operation: real time fault isolation and simulated modeling. Real time fault isolation of components is accomplished on a power system breadboard through the Fault Isolation Expert System (FIES II) interface with a rule system developed in-house. Faults are quickly detected and displayed and the rules and chain of reasoning optionally provided on a laser printer. This system consists of a simulated space station power module using direct-current power supplies for solar arrays on three power buses. For tests of the system's ablilty to locate faults inserted via switches, loads are configured by an INTEL microcomputer and the Symbolics artificial intelligence development system. As these loads are resistive in nature, Ohm's Law is used as the basis for rules by which faults are located. The three-bus system can correct faults automatically where there is a surplus of power available on any of the three buses. Techniques developed and used can be applied readily to other control systems requiring rapid intelligent decisions. Simulated modeling, used for theoretical studies, is implemented using a modified version of Kennedy Space Center's KATE (Knowledge-Based Automatic Test Equipment), FIES II windowing, and an ADEPT knowledge base.

Wang, Caroline↗

Microwave beamed power technology improvement

The magnetron directional amplifier was tested for (1) phase shift and power output as a function of gain, anode current, and anode voltage, (2) background noise and harmonics in the output, (3) long life potential of the magnetron cathode, and (4) high operational efficiency. Examples of results were an adequate range of current and voltage over which 20 dB of amplification could be obtained, spectral noise density 155 dB below the carrier, 81.7% overall efficiency, and potential cathode life of 50 years in a design for solar power satellite use. A fabrication method was used to fabricate a 64 slot, 30 in square slotted waveguide array module from 0.020 in thick aluminum sheet. The test results on the array are discussed.

Brown, W. C.↗

Vector bosons and jets in proton collisions

Events with vector bosons produced in association with jets have been extensively studied at hadron colliders and provide high-accuracy tests of the standard model. A good understanding of these processes is of paramount importance for precision Higgs physics, as well as for searches for new physics. In particular, associated production of γ, W, or Z bosons with light-flavor and heavy-flavor jets is a powerful tool for testing perturbative QCD calculations, Monte Carlo event generators, and can also constrain the parametrizations used to describe the parton content of the proton. Furthermore, events with a W or Z boson produced with two well-separated jets can be used to distinguish between electroweak and strong production mechanisms, and to set limits on contributions of physics beyond the standard model. This review summarizes the historical theoretical developments and the state-of-the-art in the modeling of vector-boson-plus-jet physics while focusing on experimental results by the LHC collaborations in run 1 and run 2 and including comparisons with recent measurements at the Tevatron.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

In-Flight Vibration Environment of the NASA F-15B Flight Test Fixture

Flight vibration data are analyzed for the NASA F-15B/Flight Test Fixture II test bed. Understanding the in-flight vibration environment benefits design and integration of experiments on the test bed. The power spectral density (PSD) of accelerometer flight data is analyzed to quantify the in-flight vibration environment from a frequency of 15 Hz to 1325 Hz. These accelerometer data are analyzed for typical flight conditions and maneuvers. The vibration data are compared to flight-qualification random vibration test standards. The PSD levels in the lateral axis generally are greater than in the longitudinal and vertical axes and decrease with increasing frequency. At frequencies less than approximately 40 Hz, the highest PSD levels occur during takeoff and landing. Peaks in the PSD data for the test fixture occur at approximately 65, 85, 105-110, 200, 500, and 1000 Hz. The pitch-pulse and 2-g turn maneuvers produce PSD peaks at 115 Hz. For cruise conditions, the PSD level of the 85-Hz peak is greatest for transonic flight at Mach 0.9. From 400 Hz to 1325 Hz, the takeoff phase has the highest random vibration levels. The flight-measured vibration levels generally are substantially lower than the random vibration test curve.

Corda, Stephen↗

Development of a ninety string solar array simulator

A power source was developed to support testing for the Space Station Freedom Power Management and Distribution (PMAD) DC Testbed. The intent was to simulate as closely as possible the steady-state and transient responses of a solar array. Several breadboards and one thermal prototype were built and tested. Responses were successfully verified and improved upon during successive breadboards. The completed 90-string simulator consists of four power MOSFETs, four 25 watt source resistors, and four 250 watt drain source bypass resistors per string, in addition to the control circuitry.

Vasek, Thomas E.↗

Development of a ninety string solar array simulator

A power source was developed to support testing for the Space Station Freedom Power Management and Distribution (PMAD) DC Testbed. The intent was to simulate as closely as possible the steady-state and transient responses of a solar array. Several breadboards and one thermal prototype were built and tested. Responses were successfully verified and improved upon during successive breadboards. The completed 90-string simulator consists of four power MOSFETs, four 25-watt source resistors, and four 250-watt drain source bypass resistors per string, in addition to the control circuitry.

Vasek, Thomas E.↗