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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

TuFF internal WRAP for Rapid Pipeline Repair (TuFF iWRAP)

The goal of “TuFF internal WRAP for Rapid Pipeline Repair” (TuFF iWRAP) program was to develop a novel material system and placement process to fabricate structural pipe within the existing deteriorated pipelines without disruption of gas delivery. The team (University of Delaware – Center for Composite Materials (UD-CCM) and Plitzie Inc.) addressed this challenge by developing a new material feedstock and pipe in pipe (PIP) repair strategy. This allows the potential for significant cost reduction and has minimum operational impact on gas customers. The new robotic based placement design allows discontinuous placement of pipe sections creating a stand-alone structural liner within the legacy pipeline without the need for pipe shutdown. Here, the material is supplied using a tethered material feeding system and is placed and UV cured with the internal Wound Rapid Automated Placement (iWRAP) system. This provides maximum placement efficiency capable of traversing 90 angle bends in 12-inch pipe and overall design customization to meet pipe repair requirements (e.g., variable wall thickness, bridging gaps, etc.). UV-curable fiber reinforced composite material has been optimized to meet structural performance and placement/cure times. Superior strength and fatigue life has been demonstrated by improving fiber-matrix adhesion using new fiber sizing for UV resins. Rapid cure approaches using new liner and resins have been evaluated with industry. The appropriate design of the section joints has been developed and tested. We estimate coating time to be ~100 hours per mile enabling typical pipe repair within 1 week.

03 NATURAL GAS↗
NASA NTRS1995

A Probabilistic Tool that Aids Logistics Engineers in the Establishment of High Confidence Repair Need-Dates at the NASA Shuttle Logistics Depot

The NASA Shuttle Logistics Depot (NSLD) is tasked with the responsibility for repair and manufacture of Line Replaceable Unit (LRU) hardware and components to support the Space Shuttle Orbiter. Due to shrinking budgets, cost effective repair of LRU's becomes a primary objective. To achieve this objective, is imperative that resources be assigned to those LRU's which have the greatest expectation of being needed as a spare. Forecasting the times at which spares are needed requires consideration of many significant factors including: failure rate, flight rate, spares availability, and desired level of support, among others. This paper summarizes the results of the research and development work that has been accomplished in producing an automated tool that assists in the assignment of effective repair start-times for LRU's at the NSLD. This system, called the Repair Start-time Assessment System (RSAS), uses probabilistic modeling technology to calculate a need date for a repair that considers the current repair pipeline status, as well as, serviceable spares and projections of future demands. The output from the system is a date for beginning the repair that has significantly greater confidence (in the sense that a desired probability of support is ensured) than times produced using other techniques. Since an important output of RSAS is the longest repair turn-around time that will ensure a desired probability of support, RSAS has the potential for being applied to operations at any repair depot where spares are on-hand and repair start-times are of interest. In addition, RSAS incorporates tenants of Just-in-Time (JIT) techniques in that the latest repair start-time (i.e., the latest time at which repair resources must be committed) may be calculated for every failed unit This could reduce the spares inventory for certain items, without significantly increasing the risk of unsatisfied demand.

Bullington, J. V.↗
DOE OSTI2024

Investigation of Debonding Effect in Internal Replacement Pipe System Under Lateral Loading

The aging pipeline infrastructure around the world necessitates immediate rehabilitation. Internal replacement pipe (IRP) is a trenchless system offering a versatile and cost-effective solution across a variety of industries, including oil, natural gas, water, and wastewater. As a structural pipeline repair system, IRPs are subject to lateral deformation because of surface traffic loading. The present study evaluates the impact of adhesion between the host pipe and the IRP, with a focus on assessing the debonding effect on the behavior of the repair system under lateral deformation and bending. This was achieved using a comprehensive approach, including experimental, numerical, and analytical techniques. Varying levels of adhesive strength resulting from different methods of surface preparation were considered. The effectiveness of the IRP system on both discontinuous host pipes with various crack widths and continuous host pipes was also investigated. The results demonstrate that adhesive strength exerts a significant influence on the repair system, especially in the case of narrow circumferential cracks, while its impact on the continuous system is minimal. For optimal performance, it is essential to choose adhesives that possess sufficient shear strength while also accounting for the required debonding length. This approach ensures that minor discontinuities are effectively controlled, thereby enhancing the system′s fatigue life. The reliable determination of the maximum allowable shear strength for the adhesive or the debonding length can ensure that it does not negatively affect fatigue life. The findings presented in this study offer new insights into the development of trenchless repair techniques that can enhance system performance and extend service life.

Tien, Tri C. M.↗
DOE OSTI2024

Reduction of Methane Leaks through Corrosion Mitigation Pre-treatments for Pipelines with Field Applied Coatings

Corrosion of buried, coated steel pipelines transporting natural gas is a significant source of methane emissions, from pipeline venting required for maintenance and repairs and from pipeline leaks and incidents. Corrosion of steel under field applied coatings is an important safety concern for the pipeline industry. This project investigates the application of a field applied alloy over girth welds to mitigate external corrosion of buried coated steel pipelines. Various metallic coating options were considered, which were required to meet several criteria: (1) it must resist corrosion under open-circuit or mild cathodic protection conditions, (2) it must protect the substrate steel, and (3) it must not negatively affect the adhesion of the field coating. Finite element models and lab testing were performed of alloy coating compositions to identify promising alloy types underneath disbonded coatings. Polarization curves of coating alloys were generated to provide the boundary conditions for the COMSOL model to compute potential and current distributions around coated areas. Sacrificial and corrosion-resistant metal alloy coatings were evaluated and optimized using corrosion modeling and laboratory electrochemical testing, where aluminum alloy 5356 (5% Mg) and steel alloy B9 (9% Cr) were selected. Corrosion test coupons were designed and fabricated using thermal spray aluminum 5356 and welded B9 steel overlays on API 5L grade X42 line pipe steel. The corrosion test coupons, with simulated pipe coating damage, were tested in a laboratory soil box and a field pipeline site in Texas for 3-months. Corrosion test coupons were then tested for 6-months at field pipeline sites in Texas and Tennessee to quantify corrosion rates and performance of the aluminum and steel alloys under polyethylene tape and 2-part epoxy coatings, various coating holidays, and with and without cathodic protection.

03 NATURAL GAS↗
DOE OSTI2022

“Innervated” Pipelines: A New Technology Platform for In-Situ Repair and Embedded Intelligence

The overall vision pursued under the project would ultimately enable capability for real-time operational monitoring of natural gas (and other) pipeline infrastructures through the combination of in-situ repair and rehabilitation methods with embedded fiber optic sensing and associated data analytics methods and platform tools. Benefits to the public include more resilient and robust natural gas pipeline infrastructures with the potential to expand the applications of developed technologies under the program to other important areas of critical energy infrastructure in the future such as H2 pipelines and infrastructure, municipal and other civil infrastructure, as well as subsurface oil, gas, and geothermal infrastructure applications. The program has successfully demonstrated feasibility for all of the critical enabling elements and serves as a foundation for future technology maturation, deployment, and customization for other potential applications and high-priority needs into the future. Several underlying innovations have shown potential for commercial deployment and are the subject of continued development and technology transfer based upon patents submitted during the project duration.

02 PETROLEUM↗
DOE OSTI2023

A verification study of fatigue-based methods in API RP 1183 for estimating fatigue life of pipeline dents

Pipeline dents are mechanical damage caused by a third party in buried pipelines during construction or maintenance repair. Dents are recognized as a leading cause of pipeline failures for both liquid and gas transmission lines, and their assessment and management are critical to pipeline integrity. To meet the industry need, American Institute of Petroleum (API) in 2020 published a recommended practice (RP) 1183 – Assessment and Management of Pipeline Dents. This API code provides the pipeline industry “standard methods” for evaluating severity and fatigue life of pipeline dents with a single peak. This paper performed an initial verification study of fatigue-based methods prescribed in API RP 1183 for estimating fatigue life of pipeline dents. A brief review was first given to the dent fatigue-based methods, including three dent screening methods for estimating dent fatigue life in Sections 7.4.1, 7.4.2, and 7.4.3 of API 1183 and one dent assessment method for predicting fatigue life in Section 8.3.4. In order to verify these fatigue life prediction methods, a set of “standard examples” of dents provided in Annexes A.1 to A.5 of API RP 1183 were utilized in this study to calculate fatigue life, to determine restraint condition, and to evaluate both screening and assessment methods for single-peak dents. Through detailed calculations and comparisons, this study confirmed some specifications of API RP 1183, but also found some self-inconsistences and errors existing in this new API code. Furthermore, this includes the self-inconsistences between three screening methods and the self-inconsistence between the screening and assessment methods. On this basis, recommendations were made on how the operators should use API RP 1183, and what actions API should take to improve this code.

42 ENGINEERING↗
DOE OSTI2013

Estimate of the allowable dimensions of diagnosed defects in category III and IV welded pipeline joints{sup 1}

An approach for estimating the permissible dimensions of technological defects in butt welded joints in category III and IV pipelines is described. The allowable size of a welding defect is determined from the condition of compliance with the specifications on strength for a reference cross section (damaged joint) of the pipeline taking into account its weakening by a given defect.With regard to the fairly widespread discovery of technological defects in butt welded joints during diagnostics of auxiliary pipelines for thermal electric power plants, the proposed approach can be used in practice by repair and consulting organizations.

42 ENGINEERING↗
DOE OSTI2022

Pipe-in-Pipe by Rapid, Continuous, Smart Alloy Coating

Our team has developed a comprehensive solution for performing in-situ structural repairs on metal piping and pipelines. This is based on a multifaceted and integrated (experimental and computational) approach, that uses a slurry-based coating and our patented high temperature sintering process, to build new metal in a pipe-in-pipe configuration. This can be utilized in either a complete pipe-in-pipe embodiment, or for patch repairs.

42 ENGINEERING↗
DOE OSTI2022

Fiber-optic sensor packaging assessment and benchmarking for embedded sensing applications

Fiber optic-based sensing for non-destructive evaluation (NDE) and structural health monitoring of various infrastructure and energy assets is an increasingly important sensing scheme. Because of their immunity to electromagnetic interferences, versatility in sensing mechanisms and designs as well as capability for distributed sensing, the fiber optic sensing is of great interest for embedding within infrastructures using advanced manufacturing methods. However, the protection of fiber optic sensors during advanced manufacturing-based embedding is an important aspect for infrastructure monitoring in practice. While successful installation of fiber optic sensors has been accomplished through application of epoxy or adhesives on infrastructure surfaces, there has been only limited investigation of fiber protection packaging schemes which are compatible with in-situ repair techniques such as the metallic cold-spray. With increasing interest and importance of cold spray-based repair processes, the integration of fiber optic sensors simultaneously during the repair is equally important. In this work, we focus our efforts on investigating various types of packaging schemes for their compatibility and integrability on the surfaces of metallic structures such as oil and gas pipelines during an in-situ repair coating. First, we consider sandblasting using silica sand particles of various size for optical fibers on the surface of a metallic coupon as a useful proxy test of sensor packaging stability. Structural damage of packaging is characterized by means of optical microscopy and the optical integrity of embedded fiber optic cables is examined using optical backscatter reflectometry (OBR). In addition, initial investigation of metallic cold-spray embedded fiber optic cables under various packaging on metallic substrates is also considered with early conclusions and future directions.

Fiber-optic sensors, Sensors packaging, Metallic C↗
DOE OSTI2021

Calibration and field deployment of low-cost sensor network to monitor underground pipeline leakage

Recent technological advances in methane detection have improved leak detection and repair. However, current methods to reliably measure methane concentrations rely on expensive instruments or demand significant labor input. There is interest in using affordable methane sensors that are responsive to ppmv level changes in methane concentrations in both urban and rural environments for monitoring underground natural gas pipeline leaks. This is especially relevant for situations where potentially significant leaks cannot be repaired immediately or smaller leaks that require long-term monitoring and further evaluation. In this work, a low-cost sensor unit, equipped with a metal oxide sensor, was designed, built, and calibrated over a wide range of methane concentrations and environmental conditions in preparation for field application. A network of these sensors was then installed at the test site and used to measure methane concentrations at ground level above known sub-surface natural gas emissions which emulated underground gas pipeline leaks. This low-cost sensor network measured over 4 days total for the two different known leakage rates. Results demonstrate that the sensors can continuously measure relative methane variability for extended periods but require calibration for a wide range of temperature and humidity conditions to properly determine absolute gas (i.e., methane) concentrations. Furthermore, when a regression analysis was conducted to evaluate the effects of meteorological parameters on methane concentration, air temperature and wind speed have strong impacts on the concentration. Overall, the network approach allows improved identification of leak location and monitoring of underground natural gas leaks.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Assessment of Cold Spraying Mild-Steel Powder onto Mild-Steel Substrate for Development of Waste Tank Repair System - 20515

Infrastructure for nuclear waste storage and processing (e.g., waste tanks, transfer pipelines, evaporators) at the U.S. Department of Energy (DOE) Hanford Site has been in service well beyond its original design life. Past corrosion control methods at Hanford for waste tanks have not been fully successful, as evidenced by leaks forming in tank AY-102, the first double-shell tank (DST) constructed, and significant degradation detected in the primary tanks of AP-102 and AY-101. Failure of infrastructure components can pose a significant risk to the environment, worker safety, and project schedules. Therefore, remotely deployable methods for repairing and extending the service life of the existing tank waste infrastructure are needed. Cold spray has been identified as a potential technique for performing in situ repairs and material buildup for life extension of waste storage and processing infrastructure. Cold-spray repair methods and technology are well-established and are used extensively by industry and the military for making repairs using dissimilar materials. Pacific Northwest National Laboratory is evaluating the process of making repairs using mild-steel powder applied to a mild-steel substrate to minimize the galvanic corrosion potential. This paper presents the initial results for a feasibility ('go/no-go') assessment as to whether low-density deposits with sound metallurgic bonds, to build-back steel plate material, can be achieved using existing commercial cold-spray equipment. An assessment of steel-on-steel deposit is necessary to determine if cold spray is a viable candidate for DST carbon steel plate restoration/repair and thus DST service life extension. Powder properties and preparation requirements have been investigated and operating conditions and parameters for depositing a cold-spray buildup of mild steel on a mild-steel substrate have been determined. Soundness of metallurgic bonding as a function of the operating parameters exercised and results from applying cold spray to lay a deposit over simulated small-diameter flaws in 1/2-inch mild-steel plate are presented. Application of in situ cold-spray repair to the DOE complex has the potential to reduce cost and schedule impacts associated with component failures and the need to procure and construct replacement infrastructure. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1983

Practical small-scale explosive seam welding

Joining principles and variables, types of joints, capabilities, and current and potential applications are described for an explosive seam welding process developed at NASA Langley Research Center. Variable small quantities of RDX explosive in a ribbon configuration are used to create narrow (less than 0.5 inch), long length, uniform, hermetrically sealed joints that exhibit parent metal properties in a wide variety of metals, alloys, and combinations. The first major all application of the process is the repair of four nuclear reactors in Canada. Potential applications include pipelines, sealing of vessels, and assembly of large space structures.

Bement, L. J.↗
DOE OSTI2024

U.S. Offshore Pipeline and Reported Incident Datasets

The U.S. Offshore Pipeline and Reported Incident Datasets provide a compilation of data from a variety of credible resources, spatially-temporally integrated into multivariate resources. This spatial resource includes more than 80,000 points along existing and abandoned pipelines in the Gulf with matched incidents based on similar lease blocks and temporal timelines (e.g., the incident date occurs within reported pipeline lifespan), structural characteristics, geologic and seafloor data, and meteorological, oceanographic, and biochemical statistics spatially and temporally matched to each point. This is provided as both a feature class in a file geodatabase, as well as a CSV file for ease of use. The pipeline incidents table is a CSV file containing more than 900 reported incidents from 1986 to 2021, including incident date, area (Outer Continental Shelf (OCS) lease block and area code), reported causes, reported incident information, and results (i.e., cost, repairs, inspections), along with quantitative severity metrics. Field dictionaries are included for both the pipeline locations and incidents datasets, which detail field definitions. The pipeline locations field dictionary includes original resource reference information.

Advanced Infrastructure Integrity Model↗
NASA NTRS2024

NIAC Phase I Final Report Lunar South Pole Oxygen Pipeline (LSPOP)

The Lunar South Pole Oxygen Pipeline (LSPOP) Phase I NIAC, is to analyze the feasibility of constructing a pipeline at the Moon’s South Pole for transporting gaseous oxygen from point of generation to point of use. A lunar pipeline has never been pursued and will revolutionize lunar surface operations for the Artemis program and reduce cost and risk. Our starting concept is for a 5 km pipeline to transport oxygen gas from an oxygen production source, for example from our molten regolith electrolysis (MRE, currently at TRL 5, see references[1],[2],[3],[4],[5],[6] for technical discussions of the MRE process) extraction site, or any other source, to an oxygen storage/liquification plant near a lunar base. The pipeline is designed to: 1) be constructed robotically from regolith-derived metals with minimal material transferred from Earth, 2) be repairable robotically, 3) have an oxygen flow rate of ~2 kg/hour, which is commensurate with the NASA initial projected need of 10,000 kg/year, 4) operate with minimal power over the lifetime of the pipeline, with a goal of high operational reliability and the ability to survive in the lunar environment for > 10 years. We compare this concept to a pipeline concept with pipe produced on Earth and then transported to and assembled on the Moon. Both approaches will use earth-based compressors, valves, and fittings which are integrated into the pipeline on the Moon.

NIAC Phase I↗
DOE OSTI2024

A goldilocks computational protocol for inhibitor discovery targeting DNA damage responses including replication-repair functions

While many researchers can design knockdown and knockout methodologies to remove a gene product, this is mainly untrue for new chemical inhibitor designs that empower multifunctional DNA Damage Response (DDR) networks. Here, we present a robust Goldilocks (GL) computational discovery protocol to efficiently innovate inhibitor tools and preclinical drug candidates for cellular and structural biologists without requiring extensive virtual screen (VS) and chemical synthesis expertise. By computationally targeting DDR replication and repair proteins, we exemplify the identification of DDR target sites and compounds to probe cancer biology. Our GL pipeline integrates experimental and predicted structures to efficiently discover leads, allowing early-structure and early-testing (ESET) experiments by many laboratories. By employing an efficient VS protocol to examine protein-protein interfaces (PPIs) and allosteric interactions, we identify ligand binding sites beyond active sites, leveraging in silico advances for molecular docking and modeling to screen PPIs and multiple targets. A diverse 3,174 compound ESET library combines Diamond Light Source DSI-poised, Protein Data Bank fragments, and FDA-approved drugs to span relevant chemotypes and facilitate downstream hit evaluation efficiency for academic laboratories. Two VS per library and multiple ranked ligand binding poses enable target testing for several DDR targets. This GL library and protocol can thus strategically probe multiple DDR network targets and identify readily available compounds for early structural and activity testing to overcome bottlenecks that can limit timely breakthrough drug discoveries. By testing accessible compounds to dissect multi-functional DDRs and suggesting inhibitor mechanisms from initial docking, the GL approach may enable more groups to help accelerate discovery, suggest new sites and compounds for challenging targets including emerging biothreats and advance cancer biology for future precision medicine clinical trials.

59 BASIC BIOLOGICAL SCIENCES↗