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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
NASA NTRS2004

Charge-Dissipative Electrical Cables

Electrical cables that dissipate spurious static electric charges, in addition to performing their main functions of conducting signals, have been developed. These cables are intended for use in trapped-ion or ionizing-radiation environments, in which electric charges tend to accumulate within, and on the surfaces of, dielectric layers of cables. If the charging rate exceeds the dissipation rate, charges can accumulate in excessive amounts, giving rise to high-current discharges that can damage electronic circuitry and/or systems connected to it. The basic idea of design and operation of charge-dissipative electrical cables is to drain spurious charges to ground by use of lossy (slightly electrically conductive) dielectric layers, possibly in conjunction with drain wires and/or drain shields (see figure). In typical cases, the drain wires and/or drain shields could be electrically grounded via the connector assemblies at the ends of the cables, in any of the conventional techniques for grounding signal conductors and signal shields. In some cases, signal shields could double as drain shields.

Kolasinski, John R.↗
NASA NTRS1973

Multilayer flat electrical cable

Flat electrical cable is lightweight, flexible over wide temperature range, withstands continuous exposure to high levels of nuclear radiation, and can carry high currents with minimum of temperature rise. Its magnetic cleanliness is equal to or better than twisted pair of wires, and it can be terminated in conventional electrical connector.

Silverman, P. G.↗
DOE OSTI2022

3D Frequency Domain Reflectometry Digital Twin of an Electrical Cable: A First Glance

Electrical cables within nuclear power plants (NPPs) are critical components required for power, control, and instrumentation systems which may be exposed to stressors, such as elevated temperatures and gamma radiation. Such stressors can lead to a reduction in the remaining useful life of electrical cables, jeopardizing the safety of NPP systems. To evaluate the effect of stressors on the degradation of electrical cables, electrical reflectometry methods are commonly employed. Frequency domain reflectometry (FDR) is a non-destructive electrical reflectometry method that uses transmission line theory to detect degradation or impedance changes within electrical cables. However, in most cases FDR is only applied to de-energized cables, limiting the application in NPPs as the cable system must be taken offline. In this work, we explore the development of an FDR digital twin to predict the degradation of an electrical cable exposed to elevated temperature, which is expected to reduce the need for offline FDR. A 3-conductor low-voltage electrical cable was selected for evaluation of the digital twin. The fully three-dimensional digital twin was developed in COMSOL using the RF module. A cable length of 30-m and frequency bandwidth of 400 MHz was selected to mimic real-world application of FDR. Over a 1-m region, the permittivity of the insulation was varied by up to 20% to model thermal degradation. The results demonstrate accurate detection of the insulation damage region, supporting further investigation of the FDR digital twin using real-world data and machine learning for predictive damage estimation or remaining lifetime.

Spencer, Mychal P.↗
DOE OSTI2023

Effect of Measurement Temperature on Electrical Cable Frequency Domain Reflectometry Response

In nuclear power plants, electrical cables are exposed to stressors, such as elevated temperature and radiation. Evaluation of the effect of stressors on the lifetime of electrical cables can be conducted using offline electrical reflectometry techniques, such as frequency domain reflectometry (FDR). However, recent work has raised the concern that FDR measurements at temperatures higher than ambient may diminish or reduce the response due to stressors, potentially leading to incorrect predictions of electrical cable damage and lifetime. In this work, we explore the FDR response of an electrical cable exposed to an oven-based thermal stressor up to 140°C, including both ramping up and ramping down temperature. It was observed that, for both the oven entrance and exit, an increase in the FDR measurement temperature led to a decrease in the FDR reflection coefficient. In particular, it was found that the reflection coefficient at the oven entrance decreased from the ambient measurement by approximately 7%, 22%, and 36% at a temperature of 60°C, 100°C, and 140°C, respectively.

Spencer, Mychal P.↗
DOE OSTI2023

Frequency Domain Reflectometry (FDR) Simulation Techniques for Digital Twin Representation of an Electrical Cable

Simulation of cable system response to frequency domain reflectometry (FDR) tests can be instrumental to understanding these tests and the nature and influence of various cable anomalies on test signatures. Reflectometry simulations are based upon a finite element representation of cable conductors and insulation to produce an S-parameter at each evaluated frequency. The aggregate collection of cable model S-parameters can simulate the influence on a test signal injected into a physical cable. Such an approach was undertaken in this work to produce a digital twin simulation of a low-voltage electrical cable. The electrical cable digital twin examined the influence of test simulation parameters and the relative influence of cable anomalies, including thermal aging, water or moisture exposure, water or moisture ingress, and other anomalies. The digital twin in this work included modeling of the conductors, insulation, jacket, and surrounding environment (air, water, etc.). The digital twin could be expanded to include cable bends, junctions and splices, branch or T systems, and termination impedances of motors or instruments. Observations and conclusions of this work include: 1. Fully 3D digital twin simulation of an electrical cable using an FDR approach is possible. However, there are tradeoffs between simulation fidelity and solution time, which must be balanced to ensure the simulation solves in an adequate amount of time (e.g., less than 20 minutes). Simulation parameters to balance include frequency bandwidth, number of frequencies, mesh density, connection impedance, and permittivity tolerance. 2. The digital twin simulation can explain FDR sensitivity to various cable anomalies, including entry and exit from an oven or water bath. 3. The digital twin simulation FDR response attenuates with distance along the cable and is further affected by the frequency bandwidth, which is similar to that observed with physical measurements. 4. The resolution of the digital twin FDR peaks increased with increasing bandwidth and with increasing number of frequencies, again similar to physical measurements. 5. The presence of multiple anomalies in the digital twin does not substantially attenuate the FDR response to anomalies located beyond the first encountered anomaly and impedance mismatch. 6. Spectral variation of the permittivity did not have a significant effect on the FDR response compared to a fixed nominal value. 7. Extension of the digital twin to 1000 ft still allowed for detection of distal anomalies near the far end of the electrical cable from the instrument connection point. 8. The ARENA test bed facilitates efficient NDE evaluations of well understood cable anomalies with various NDE methods without risking actual plant damage.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Color Change During Thermal Degradation of Polyolefin Electric Cable Insulations

Color change of electric cable insulations used in nuclear power plants (NPPs) is a non-destructive, quick and inexpensive technique to measure degradation. Quantification of color change is facilitated by a light booth of CIE D65 illuminant, a commercial camera and open-source software ImageJ with micaToolbox plugin. Yellowness index (YI) and total color difference (?E) are calculated from calibrated photos of a white cross-linked polyethylene (XLPE) and a black ethylene-propylene rubber (EPR) based specimens aged at 110°C, 121°C, 136°C and 150°C after 1~640 days. Using the same setup and software, pixelwise ?E profile is determined for the cross-sectional photo of a white EPR specimen, where heterogeneous aging is detected.

cable aging, color analysis↗
DOE OSTI2021

Application of Principal Component Analysis for the Monitoring of the Aging Process of Nuclear Electrical Cable Insulation

To ensure the safe operation of nuclear power plants (NPPs), it is critical to understand how NPP electrical cable insulation will degrade under different service environments. In this study, various nondestructive examination methods were selected to evaluate degradation of electrical cable insulation after aging. Elongation at break, indenter modulus, relaxation constant, mass change, total color difference, and carbonyl index were collected stepwise on cross-linked polyethylene (XLPE) cable insulations after predetermined exposure intervals. Three different insulation aging scenarios were investigated: 1) simultaneous irradiation and heating at 150°C, 2) heating at 150°C followed by corresponding times of irradiation at ambient temperature, and 3) irradiation at ambient temperature followed by heating at 150°C for the same duration. A constant dose rate of 300 Gy/hr was selected with a total gamma irradiation absorbed dose up to 320 kGy. To gain insight into the long-term performance of NPP electrical cable insulation, principal component analysis (PCA), a data-driven approach, was utilized to identify key indicators of cable insulation degradation. By reducing the dimensionality of the data while retaining degradation information, PCA was used to highlight the changes in the measured properties under gamma irradiation according to total absorbed dose and the different aging scenarios.

Li, Donghui↗
NASA NTRS2013

Vibration Testing of Electrical Cables to Quantify Loads at Tie-Down Locations

The standard method for defining static equivalent structural load factors for components is based on Mile s equation. Unless test data is available, 5% critical damping is assumed for all components when calculating loads. Application of this method to electrical cable tie-down hardware often results in high loads, which often exceed the capability of typical tie-down options such as cable ties and P-clamps. Random vibration testing of electrical cables was used to better understand the factors that influence component loads: natural frequency, damping, and mass participation. An initial round of vibration testing successfully identified variables of interest, checked out the test fixture and instrumentation, and provided justification for removing some conservatism in the standard method. Additional testing is planned that will include a larger range of cable sizes for the most significant contributors to load as variables to further refine loads at cable tie-down points. Completed testing has provided justification to reduce loads at cable tie-downs by 45% with additional refinement based on measured cable natural frequencies.

Dutson, Joseph D.↗
DOE OSTI2021

Evaluation of Oxygen Consumption as a Sensitive Measure of Electrical Cable Polymer Insulation Degradation

Polymers used as dielectric materials in nuclear grade electrical cables, such as cross-linked polyethylene (XLPE) and ethylene-propylene rubber (EPR), are long-lived and durable. Estimating the decades-long useful service life of polymers experimentally in a feasible timeframe of weeks or months requires greatly accelerated aging in the laboratory at elevated temperatures and/or gamma dose rates. Many limitations of accelerated aging, such as due to artefacts of the process including diffusion limited oxidation and dose rate effects, have been identified that can make accurate lifetime prediction at service conditions challenging. This can be due to differences in degradation mechanisms between rapid and extended aging or to the presence of induction periods during which early aging is undetectable using common metrics of polymer insulation characterization such as tensile elongation at break. Conceptually, an ideal measure of aging would track clearly and predictably with material changes throughout the lifecycle of the evolving material state from early aging through end of useful life. With such a metric accelerated aging could be performed at much milder conditions, conditions closer to those found in long term service, and end of life calculated from the early data. Oxygen consumption has previously been proposed as a sensitive measure of insulation polymer oxidation that might meet such desirable characteristics. In this work, nuclear cable insulation samples of the two most common types, XLPE and EPR, from two of the most sourced manufacturers, RSCC and The Okonite Company, were subjected to gamma irradiation at dose rates of 100, 200, and 300 Gy/hr for up to 42 days at 26°C. The aged samples were used to evaluate oxygen consumption as a sensitive measure of aging for these materials and these conditions. For comparison and validation, the aged samples were also characterized using the more conventional tests of mass change, density, carbonyl index, and yellowness index. For both materials, oxygen consumption during irradiation was found to track consistently with applied dose—oxygen consumption rate was linear with time. Mass change and carbonyl index were also clearly proportional to exposure dose. Yellowness index, a surface sensitive measure, was observed to increase linearly with dose at low exposure levels before plateauing. Sample density was not observed to change under the conditions explored. Oxygen consumption was found to be a particularly sensitive metric to measure the degradation of polymeric cable insulation exposed to radiation. Oxygen consumption was compared to Arrhenius and time-temperature-superposition methods for activation energy calculation using literature date and found to be a useful and viable alternative for lifetime prediction. The techniques developed in this work are anticipated to be valuable in the estimation of insulation aging rates under mild conditions approaching service conditions. Direction comparison of useful life prediction by oxygen consumption with prediction via Arrhenius methodology for thermal aging and existing methods for radiation and combined thermal/radiation aging would serve to further validate this promising approach and refine our understanding of material-specific aging rates.

36 MATERIALS SCIENCE↗
NASA NTRS1972

Microbiological sampling of returned Surveyor 3 electrical cabling

A piece of electrical wiring bundle running from the television camera to another part of the spacecraft was selected for microbiological examination. Sampling methods are discussed. The results presented show that no viable microorganisms were recovered from the part of the Surveyor 3 cable which was tested. Factors that could have contributed to the sterility of the cable are thermal vacuum testing, natural dieoff, change in pressure during launch, and lunar vacuum and temperature.

Knittel, M. D.↗
NASA NTRS1986

Rotating Connection for Electrical Cables

Cable reel provides electrical connections between fixed structure and rotating one. Reel carries power and signal lines while allowing rotating structure to turn up to 360 degrees with respect to fixed structure. Reel replaces sliprings. Can be used to electrically connect arm of robot with body. Reel releases cable to rotating part as it turns and takes up cable as rotating part comes back to its starting position, without tangling, twisting, or kinking.

Manges, D. R.↗
DOE OSTI2021

Optical fiber based sensing for smart electrical cables and distributed radiation detection

A cable device includes a sheath member, a number of electrical cables provided within the sheath member, and an optical fiber sensing member provided within the sheath member. The optical fiber sensing member includes a functionalized optical fiber based sensor device structured to exhibit a change in one or more optical properties in response to changes in a parameter of interest. Also, a method of sensing radiation includes introducing a source light into an optical fiber sensing member provided within a structure, wherein the optical fiber sensing member comprises a functionalized optical fiber based sensor device structured to exhibit a change in one or more optical properties in response to radiation, detecting sensing light generated in response to the source light, and determining a radiation level at a plurality of locations within the structure using the detected sensing light and a distributed sensing scheme.

Chen, Peng Kevin↗
NASA NTRS1976

Electrical-cable design guide

Formulas and tables are provided to aid designers in determining electrical cable jacket sizes, number of wires per lay pattern, filler material requirements, jacket wall thickness, and overall cable diameters.

Phelps, G. A.↗
NASA NTRS1992

Material selection and evaluation of new encapsulation compounds for electric cables for launch support system

Eight urethane compounds were evaluated as possible replacement for the existing encapsulating compoounds for electrical cables for the Launch Support System at Kennedy Space Center (KSC). The existing encapsulating compound, PR-1535, contains the curative MOCA 4-4'-Methylene-BIS (2-chloroaniline), which is a suspect carcinogen and hence may be the subject of further restrictions of its use by the Occupational Safety and Health Administration (OSHA). The samples made in the configuration of cable joints and in the form of disks were evaluated for flammability and hypergolic compatibility. These also underwent accelerated weatherability tests that measured the residual hardness of the exposed samples. Three candidates and the existing compound passed the hardness test. Of these, only one candidate and the existing compound passed the flammability test. The thermal and hydrolytic stability (weatherability) of these samples was studied using thermogravimetric analysis (DSC) techniques. The TMA and DSC data correlated with the residual hardness data; whereas, the TGA data showed no correlation. A hypergolic compatibility test will be conducted on the compound V-356-HE80, which passed both the flammability and accelerated weatherability tests.

Ray, Asit K.↗
DOE OSTI2022

Extension of Cable Electrical Assessment Techniques to Detect and Discriminate Radiation Aging on Cable Insulation Systems (Abstract)

The purpose of this study of the electrical responses of gamma radiation aged low voltage nuclear cables is to advance tools to determine cable condition (extent of damage) and identify degradation location along the cable length. The developed technology will provide nuclear plant operators with the options to focus cable repair, mitigation, or replacement efforts locally and avoid wholesale cable replacement.

42 ENGINEERING↗
DOE OSTI2023

Dose Rate Effects on Degradation of Nuclear Power Plant Electrical Cable Insulation at a Common Dose

The intent of this report is to address an identified knowledge gap in relating accelerated aging of nuclear electrical cables to service aging: dose rate effects (DRE). Here, DRE refer to gamma radiation-induced polymer degradation being a function of dose rate in addition to total absorbed dose. The concern raised is that historical qualification conducted at higher dose rates to simulate service lifetime may underestimate insulation degradation that occurs at lower dose rates in service. In the work described herein, common nuclear cable insulation materials—cross-linked polyethylene (XLPE) and ethylene propylene diene elastomer (EPDM)—were subjected to accelerated aging at ambient temperature (26°C) at different gamma dose rates of 100, 200 and 1800 Gy/h for select exposure durations to achieve constant total doses of 170, 210 and 300 kGy to evaluate DRE. First, the cable insulation material types investigated are described. Then, the accelerated aging experimental process involving gamma irradiation applied to the insulation specimens at room temperature and different dose rates is discussed. Then, the experimental characterization techniques used to perform this work are elucidated. These include elongation at break (EAB), mass change, yellowness index (YI), carbonyl index (CI), density, indenter modulus (IM), and relaxation constant (t). Theory of polymer degradation is discussed, and characterization results and discussion are provided. Finally, concluding remarks are made. The findings from this work and cited prior work reveal that DRE are material dependent, even between similar material categories (e.g., XLPE). In the case of the EPDM studied, degradation of ductility was observed to be greater at higher dose rate for the same total dose, indicating accelerated gamma aging to be more conservative than extended aging. Thus, conclusions regarding the conservatism of historical qualification likely require additional consideration for specific materials and conditions in question. The results of this study support the contention that, due to inherent limitations and uncertainties associated with prediction of cable remaining useful life from accelerated aging experiments, trending of installed cable insulation health status will be more practical and useful for safe and efficient cable aging management repair and replace decisions than lifetime prediction from historical qualification. The combination of material robustness demonstrated by the qualification process and ongoing monitoring of cable health status combine to provide confidence in continued safe use of existing nuclear cables. Additional research into effective and efficient condition monitoring methods for non-destructive evaluation of installed cables is needed to support aging cable management, including material studies to inform interpretation of measured results.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗