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Digital image correlation through a rigid borescope.
There occasionally occur situations in field measurements where direct optical access to the area of interest is not possible. In these cases the borescope is the standard method of imaging. Furthermore, if shape, displacement, or strain are desired in these hidden locations, it would be advantageous to be able to do digital image correlation (DIC) through the borescope. This paper will present the added complexities and errors associated with imaging through a borescope for DIC. Discussion of non-radial distortions and their effects on the measurements, along with a possible correction scheme will be discussed.
Modeling the measured effect of a nitroplasticizer (BDNPA/F) on cookoff of a plastic bonded explosive (PBX 9501)
Here, we have used a modified version of the Sandia Instrumented Thermal Ignition (SITI) experiment to develop a pressure-dependent, five-step ignition model for a plastic bonded explosive (PBX 9501) consisting of 95 wt% octahydro-1,3,5,7-tetranitro-1,3,5,7-tetrazoncine (HMX), 2.5 wt% Estane® 5703 (a polyurethane thermoplastic), and 2.5 wt% of a nitroplasticizer (NP): BDNPA/F, a 50/50 wt% eutectic mixture bis(2,2-dinitropropyl)-acetal (BDNPA) and bis(2,2-dinitropropyl)-formal (BDNPF). The five steps include desorption of water, decomposition of the NP to form NO2, reaction of the NO2 with Estane® and HMX, and decomposition of HMX. The model was fit using our experiments and successfully validated with experiments from five other laboratories with scales ranging from about 2 g to more than 2.5 kg of PBX. Our experimental variables included density, confinement, free gas volume, and temperature. We measured internal temperatures, confinement pressure, and ignition time. In some of our experiments, we used a borescope to visually observe the decomposing PBX. Our observations included the endothermic β–δ phase change of the HMX, a small exothermic temperature excursion in low-density unconfined experiments, and runaway ignition. We hypothesize that the temperature excursion in these low density experiments was associated with the NP decomposing exothermically within the PBX sample. This reactant-limited temperature excursion was not observed with our thermocouples in the high-density experiments. For these experiments, we believe the binder diffused to the edges of our high density samples and decomposed next to the highly conductive wall as confirmed by our borescope images.
Miniature motorized inspection tool for DOE Hanford site tank bottoms - 15700
Recently, small amounts of waste have been found in the annulus of tank AY-102, prompting the need for developing inspection tools that can identify the cause and location of the leak. Three separate access paths can be used to obtain information regarding the tank bottom condition. The inspection may be conducted via: 1) Refractory air slots through the annulus; 2) 4'' annulus air supply pipe to central air slots; 3) 6'' leak detection pit drain from the central sump. There are various environmental and physical constraints which the tool will have to adhere to. In order for the tool to be successful, it must be capable of the following: Travel through small cooling channels with dimensions as small as 1.5'' x 1.5''; Provide live video feedback; Produce enough torque to overcome the tether drag force; Inverted travel to avoid obstacles such as tank corrosion; Navigate up to 38 feet to the tank center, while maneuvering through four 90 deg. turns. A model of the inspection tool has been designed, assembled and reported. Areas of potential performance improvement were observed; these areas are the basis of the following design, as seen above. The changes include: The addition of an additional 4 wheels; Body modification to house the camera; A loft on the bottom from the tools edge to the magnets lowest edge; Shaving the hubs of the current wheels; Control method changed to a joystick. The tank configuration through which the tool will have to maneuver are the following: 72 outer ring slots (1.5'' x 1.5'' x 17'); 36 ring slots (2'' x 1.5'' x 12'); 18 inner slots (3'' x 1.5'' x 7'). The components used for this design iteration are not radiation hardened nor are they designed to withstand elevated temperatures. However, this prototype has been constructed with the final goal of being radiation hardened and able to withstand elevated temperatures in mind. The components that make up this design iteration are the following: Arduino Uno board with ATMega328 micro-controller; Joystick shield kit for the Arduino Uno; Eggsnow USB Borescope Endoscope 5.5 mm inspection camera; 136:1 Sub-micro Plastic Planetary Gearmotor; 14 x 4.5 mm wheels; 3D-printed body; 3D-printed free rolling shafts; Neodymium magnet - 1 h x 3/8 h x 1/16 h; 4.53 lb pull force. In the time to come, there are a few goals that are to be completed. The first group of tasks is associated with the testing and recording of data of the current prototype. This data will be analyzed and appropriate action will be taken based on the results of the testing. The testing will include simulating the challenges that the tool will face in the AY-102 tank. Working with the Hanford DOE site, a bag of Kaolin 2200 will be acquired to be used for the test bed to simulate tank conditions. Further modification will then be made to enable the tool to be able to maneuver through a 90 deg. turn. Completion of this task will be a major milestone, as this tool will be readily usable in the other tanks containing HLW; as other tanks will be easier to maneuver through.
Void fraction, bubble size and interfacial area measurements in co-current downflow bubble column reactor with microbubble dispersion
Micro-bubbles dispersed in bubble column reactors have received great interest in recent years, due to their small size, stability, high gas-liquid interfacial area concentrations and longer residence times. The high gas-liquid interfacial area concentrations lead to high mass transfer rates compared to conventional bubble column reactors. In the present work, experiments have been performed in a down-flow bubble column reactor with micro-bubbles generated and dispersed by a novel mechanism to determine the gas-liquid interfacial area concentrations by measuring the void fraction and bubble size distributions. Gamma-ray densitometry has been employed to determine the axial and radial distributions of void fraction and a high speed camera equipped with a borescope is used to measure the axial and radial variations of bubble sizes. Also, the effects of superficial gas and liquid velocities on the two-phase flow characteristics have been investigated. Further, reconstruction techniques of the radial void fraction profiles from the gamma densitometry's chordal measurements are discussed and compared for a bubble column reactor with dispersed micro-bubbles. The results demonstrate that the new bubble generation technique offers high interfacial area concentrations (1,000 to 4,500 m 2 /m 3 ) with sub-millimeter bubbles (500 to 900 µm) and high overall void fractions (10% – 60%) in comparison with previous bubble column reactor designs. The void fraction data was analyzed using slip velocity model and empirical correlation has been proposed to predict the Sauter mean bubble diameter.
Large deformation and gas retention during cookoff of a plastic bonded explosive (PBX 9407)
Here, we have used several configurations of the Sandia Instrumented Thermal Ignition (SITI) experiment to develop a pressure-dependent, four-step ignition model for a plastic bonded explosive (PBX 9407) consisting of 94 wt.% RDX (hexahydro-1,3,5-trinitro-1,3,5-triazine), and a 6 wt.% VCTFE binder (vinyl chloride/chlorotrifluoroethylene copolymer). The four steps include desorption of water, decomposition of RDX to form equilibrium products, pressure-dependent decomposition of RDX forming equilibrium products, and decomposition of the binder to form hydrogen chloride and a nonvolatile residue (NVR). We address drying, binder decomposition, and decomposition of the RDX component from the pristine state through the melt and into ignition. We used Latin Hypercube Sampling (LHS) of the parameters to determine the sensitivity of the model to variation in the parameters. We also successfully validated the model using one-dimensional time-to-explosion (ODTX and P-ODTX) data from a different laboratory. Our SITI test matrix included 1) different densities ranging from 0.7 to 1.63 g/cm 3 , 2) free gas volumes ranging from 1.2 to 38 cm 3 , and 3) boundary temperatures ranging from 170 to 190 °C. We measured internal temperatures using embedded thermocouples at various radial locations as well as pressure using tubing that was connected from the free gas volume (ullage) to a pressure gauge. We also measured gas flow from our vented experiments. A borescope was included to obtain in situ video during some SITI experiments. We observed significant changes in the explosive volume prior to ignition. Our model, in conjunction with data observations, imply that internal accumulation of decomposition gases in high density PBX 9407 (90% of the theoretical maximum density) can contribute to significant strain whether or not the experiment is vented or sealed.
Cookoff experiments of a melt cast explosive (Comp-B3)
Validated models of melt cast explosives exposed to accidental fires are essential for safety analysis. In the current work, we provide several experiments that can be used to develop and validate cookoff models of melt cast explosives such as Comp-B3 composed of 60:40 wt% RDX:TNT. We present several vented and sealed experiments from 2.5 mg to 4.2 kg of Comp-B3 in several configurations. We measured pressure, spatial temperature, and ignition time. Some experiments included borescope images obtained during both vented and sealed decomposition. We observed the TNT melt, the suspension of RDX particles in the melt, bubble formation caused by RDX decomposition, and bubble-induced mixing of the suspension. The RDX suspension did not completely dissolve, even as temperatures approached ignition. Our results contrast with published measurements of RDX solubility in hot TNT that suggest RDX would be completely dissolved at these high temperatures. These different observations are attributed to sample purity. We did not observe significant movement of the two-phase mixture until decomposition gases formed bubbles. Bubble generation was inhibited in our sealed experiments and suppressed mixing.
Characterization of Saltstone Grout Line Samples
During a prestart recirculation operation in the Saltstone Processing Facility (SPF), operations staff noticed hardened scaling falling into the hopper. As a result, SPF operators and Saltstone Engineering decided to postpone operation and conduct a process room hopper cleanout. During the cleanout effort personnel noted greater than normal buildup of damp solid material in the transfer line. A borescope investigation was conducted and confirmed buildup was present throughout the transfer line to the downstream valves. Savannah River National Laboratory personnel were asked to characterize the scale material and samples collected from the saltstone grout line and provide recommendations and/or further guidance as to whether additional corrosion testing is needed for useful equipment operating life information. Based on the samples characterized results, the plug material contained only the 60:40 slag:fly ash saltstone. Portland cement in the original 10:45:45 Portland cement:slag:fly ash mix may result in a less abrasive slurry compared to the 60:40 slag:fly ash mix because the slag is > 95 % crushed angular, sharp edged glass. Saltstone grout erosion and corrosion testing of A36 carbon steel is needed to determine if the 60:40 mix is more abrasive and corrosive for A36 carbon steel than the 10:45:45 mix.
The effect of inhomogeneities in coal-based mesophase pitch on filament formation and melt spinning for carbon fiber
Mesophase pitch-based carbon fibers excel as high specific strength and modulus materials, but challenges in stable, continuous melt spinning processing are a serious limiting factor. Inhomogeneities in the pitch may result in flow instabilities that can lead to filament breakage. This work aims to characterize and offer mitigation strategies for the negative effects that inhomogeneities such as isotropic binder, gels, and other inclusions impart on melt spinning of mesophase pitch. The effect of inhomogeneities on spinning stability are analyzed using capillary rheometry, borescope imaging of elongating filaments, and filtration. With no filter, immediate blockage of the spinning capillary occurred. Improvement in melt spinning duration was observed when a porous metal filter (20 μm nominal pore size) was utilized, but no significant further improvement in spinning duration was found upon decreasing the filter nominal pores size to 10, 5 and 2 μm. Moreover, flow instabilities that disrupted melt spinning stability were observed by capillary rheometry when the size of included isotropic pitch domains were larger than approximately 10 μm. Resultant carbon fiber properties and SEM imaging of fracture surfaces are reported.
Fiber Optic Instrumentation in High Temperature Irradiation Environments
The extremely harsh conditions of advanced reactor designs pose serious challenges for nuclear fuels and materials. Traditional instrumentation (thermocouples, strain gauges, etc.) are not well suited for extended operation in such a harsh environment. This work discusses the potential for using fiber optic-based instrumentation in high temperature irradiation experiments. The primary limitation of fiber optic instrumentation in irradiation experiments is signal darkening due to attenuation in the fiber material. A computational model has been developed to predict broadband optical attenuation in fused silica fiber materials as a function of time, temperature, and dose. Preliminary results obtained using this model are shown for one cycle of irradiation in the high flux isotope reactor at various temperatures. An irradiation campaign has been initiated to provide temperature-dependent optical attenuation data at high dose in order to validate the predictive model. Demonstration of the safety and reliability of new and enhanced nuclear fuels and materials is essential for improving the safety and reliability of existing nuclear power plants and for the licensing and operation of advanced nuclear reactor technologies. Experimental validation of fuel performance codes requires high fidelity measurements during instrumented irradiation experiments. Therefore, a clear need exists for sensors of unprecedented accuracy, resolution, time/space/energy spectrum dependence, reduced size, and, perhaps most importantly, performance in harsh environments. The harsh environment during accelerated irradiation testing could include temperatures from 300 deg. C up to 2600 deg. C, and radiation damage levels ranging from 1 to greater than 100 dpa. Optical fiber-based sensors are a promising candidate for instrumentation in high temperature irradiation environments. Optical fibers are small, inexpensive, chemically inert, immune to electromagnetic interference, and made of high temperature radiation-hard materials. The ability to make distributed measurements of temperature or strain using a single inexpensive optical fiber currently exists for non-extreme environments as commercially available technology. Other advanced sensing technologies such as laser ultrasound, borescopes, and laser-induced breakdown spectroscopy use fiber optic light delivery as a critical component of the sensor design. Some potential applications for optical fiber-based sensors in instrumented irradiation experiments include in-situ measurements of thermal conductivity, ultrasonic measurement of elastic constants (with fiber optic delivery of signal for generation and detection of ultrasonic wave), and distributed measurements of temperature and/or strain (i.e., swelling). The primary limitation for the use of optical technologies for harsh environment (e.g., high neutron flux reactor environments) instrumentation is the attenuation of the light signal due to the effects of temperature and/or irradiation. This work summarizes initial efforts towards developing a predictive model of temperature-dependent radiation-induced attenuation in fused silica optical fibers at high dose. If there is adequate transmission in the fibers, fiber optic-based instrumentation could provide highly accurate distributed measurements during instrumented fuel/material irradiation experiments. Preliminary results show attenuation on the order of 5- 10 dB/m in the wavelength range of 750-900 nm at temperatures of 300 deg. C and below after one HFIR cycle (24 days). At higher temperatures (600 and 900 deg. C), the attenuation is reduced below 5 dB/m in the same wavelength range. This amount of attenuation is acceptable for most fiber optic based sensor systems with a dynamic range on the order of 20-50 dB for a reasonable length (1-2 meters) of fiber in the high flux region. Many optical components use a wavelength of 850 nm, which lies in the low attenuation window. In order to refine and ultimately validate the predictive model of optical fiber attenuation, a reactor irradiation campaign has been initiated. Rabbit irradiation capsules have been designed to irradiate optical fiber material (low and high OH fused silica, as well as single crystal sapphire) specimens in the HFIR at temperatures ranging from 100 to 1200 deg. C. (authors)
Determining Drying Conditions to Mitigate Hanford Transfer Line Corrosion
Radioactive waste is stored in underground, carbon-steel double-shell tanks at the Department of Energy Hanford site.1,2,3 The underground transfer lines are used to transfer the waste between the tanks and other assets at the Hanford tank farm facilities. The transfer lines constructed before 1990 are pipe-in-pipe design with most of the lines having carbon steel carrier pipe and carbon steel encasements. The lines constructed after 1990 have a stainless-steel carrier with a carbon steel encasement. The carrier lines, which are in contact with the waste, provide a critical confinement function, while the encasements provide secondary containment to reduce the risk of a release and contamination to the environment. In 2022, a visual inspection of the annulus between the encasement and the carrier for one of the pre-1990 transfer lines revealed standing liquid in contact with the carrier pipe. Additionally, a significant build-up of corrosion products on the exterior of the carrier pipe and the interior of the encasement pipe was observed. To assess the extent of condition, borescope inspections were performed in the encasement space of additional transfer lines in the facility to provide a baseline. The inspection revealed that of the lines inspected, 29 had either moisture present or evidence that moisture had been present in the past (e.g., waterline corrosion where the pipe had been exposed to standing water). Additional inspections indicated several instances of pitting corrosion on the interior of the encasement and exterior the carrier transfer lines. An image of the carrier pipe with several pits is presented in Figure 1(a) and the profiled image of the transfer line section along with the pit depths are presented Figure 1(b). As seen in the figure, the deepest pit was 73 mils on the pipe section. These lines were designated as “do-not-use” until further compensatory actions are implemented to return the lines to service.
RadiationHardened Visual Inspection Systems for Nuclear Energy (Phase I Final Report)
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High-Radiation-Tolerant Vision Systems for Nuclear Energy Phase I Final Report
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