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At least 19 records

Conduct of Engineering Project Engineer Qualification Standard

This document describes the training and qualification requirements for the Project Engineer (PE) position at the Los Alamos National Laboratory (LANL). Analysis indicates that the Project Engineer position is not required to meet the requirements of DOE Order 426.2, Personnel Selection, Training, Qualification, and Certification Requirements for DOE Nuclear Facilities for “Technical Staff” positions. However, Engineering Services Division (ESD) has decided to hold their Project Engineers to a higher professional standard by developing a qualification program for the PEs.

42 ENGINEERING↗

Design Engineer Qualification Standard

This document describes the training and qualification requirements for the Design Engineer (DE) position at Los Alamos National Laboratory (LANL). A Design Engineer translates design inputs into design output documents using design analysis and calculations, national codes and standards, DOE orders and standards, maintenance considerations, LANL best practices, and complex-wide lessons learned. Analysis performed by a DE requires sufficient detail in the purpose, method, assumptions, design input, references, and units such that a qualified engineer is able to review and understand the content and verify the adequacy of the results without recourse to the originator. A DE is assigned to a project by Engineering Management.

42 ENGINEERING↗

Qualification of Engineering Camera for Long-Duration Deep Space Missions

Qualification and verification of advanced electronic packaging and interconnect technologies, and various other types of hardware elements for the Mars Exploration Rover s Spirit and Opportunity (MER)/Mars Science Laboratory (MSL) flight projects, has been performed to enhance the mission assurance. The qualification of hardware (engineering camera) under extreme cold temperatures has been performed with reference to various Mars-related project requirements. The flight-like packages, sensors, and subassemblies have been selected for the study to survive three times the total number of expected diurnal temperature cycles resulting from all environmental and operational exposures occurring over the life of the flight hardware, including all relevant manufacturing, ground operations, and mission phases. Qualification has been performed by subjecting above flight-like hardware to the environmental temperature extremes, and assessing any structural failures or degradation in electrical performance due to either overstress or thermal cycle fatigue. Engineering camera packaging designs, charge-coupled devices (CCDs), and temperature sensors were successfully qualified for MER and MSL per JPL design principles. Package failures were observed during qualification processes and the package redesigns were then made to enhance the reliability and subsequent mission assurance. These results show the technology certainly is promising for MSL, and especially for longterm extreme temperature missions to the extreme temperature conditions. The engineering camera has been completely qualified for the MSL project, with the proven ability to survive on Mars for 2010 sols, or 670 sols times three. Finally, the camera continued to be functional, even after 2010 thermal cycles.

Ramesham, Rajeshuni↗

AMS-02 Cryocooler Baseline Configuration and Engineering Model Qualification Test Results

Four Sunpower M87N Stirling-cycle cryocoolers will be used to extend the lifetime of the Alpha Magnetic Spectrometer-02 (AMS-02) experiment. The cryocoolers will be mounted to the AMS-02 vacuum case using a structure that will thermally and mechanically decouple the cryocooler from the vacuum case while providing compliance to allow force attenuation using a passive balancer system. The cryocooler drive is implemented using a 60Hz pulse duration modulated square wave. Details of the testing program, mounting assembly and drive scheme will be presented. AMS-02 is a state-of-the-art particle physics detector containing a large superfluid helium-cooled superconducting magnet. Highly sensitive detector plates inside the magnet measure a particle s speed, momentum, charge, and path. The AMS-02 experiment, which will be flown as an attached payload on the International Space Station, will study the properties and origin of cosmic particles and nuclei including antimatter and dark matter. Two engineering model cryocoolers have been under test at NASA Goddard since November 2001. Qualification testing of the engineering model cryocooler bracket assembly is near completion. Delivery of the flight cryocoolers to Goddard is scheduled for September 2003.

Banks, Stuart↗

RL10A-3-3B high mixture ratio qualification program

The results of the high mixture ratio qualification testing of the RL10 engine for the Shuttle/Centaur program are presented. The objective of the engine qualification test was to demonstrate the suitability of the RL10A-3-3B engine for space vehicle flight by subjecting it to the testing specified in RL10A-3-3B Model Specification Number 2295 dated February 1986. The applicable section of the specification is presented. Due to payload volume advantages which can be achieved by increasing the operating mixture ratio of the RL10, a decision was made to qualify the engine to run at a higher mixture ratio. A program was created to qualify the RL10 engine for operation at 15,000 pounds thrust and a nominal 6.0 to 1 mixture ratio. This model of the engine was designated the RL10A-3-3B. The qualification program included three test series as follows: (1) hardware durability and limits test in which the engine completed 23 firings and 4605.7 seconds with 1588.7 seconds at less than 6.6 mixture ratio; (2) preliminary qualification test in which the engine completed 26 firings and 5750 seconds; and (3) qualification test in which the engine completed 26 hot firings and 5693.4 seconds with 905.9 seconds at 6.7 mixture ratio. Several changes in engine hardware were required for operation of the RL10A-3-3B engine in the Space Shuttle which include a duel pressure switch ignition, an oxidizer flow control, and helium plumbing changes.

Vogel, T.↗

Assessment and Usage of In-Situ Monitoring Data for American Society of Mechanical Engineers Part Qualification

In-situ monitoring and anomaly detection are important components for qualification of directed energy deposition (DED) additive manufacturing (AM) processes and components. The use of in-situ monitoring requires an understanding of anomalies that can be identified during the process and how those anomalies correlate to mechanical properties of the component post-production. There is also a need to qualify the algorithms and software used to interpret the process signals for DED AM. There is no single process signal that can be used with a single algorithm that will identify all anomalies that will translate to a defect in a process. The process signals are affected by changes in material, location, resolution, acquisition rate, component geometry, and the machine itself. It is observed that multiple process signals are required to identify relevant features that can be correlated to mechanical properties.

36 MATERIALS SCIENCE↗

X-33 Leading the Way to VentureStar(Trademark) in this Decade

The X-33, reusable space plane technology demonstrator is on course to begin the flights of the X-33 by the end of 2002 that will serve as a basis for industry and government decisions that could lead to VentureStar(Trademark). Lockheed Martin has placed the VentureStar(Trademark) LLC in it's Space Company and is now competing in an industry wide effort that will permit NASA to select a Second Generation RLV source by 2005. This move provides the focus for firm business planning needed to enable the decision by the time X-33 flies in mid 2002 and possibly with upgraded technologies a year or so later. Since the IAF 50th Congress in Amsterdam, most of the major hardware elements of X-33 have been through their assembly and test. The flight liquid oxygen tank was the first major element to complete final assembly. Aerospike Engine qualification testing has progressed successfully through its test objectives and the two flight engines are in preparation to be delivered to the Assembly Facility in Palmdale. All Thermal Protection System (TPS) metallic panels have completed qualification testing and have been delivered to Palmdale and all remaining TPS elements have been assembled and are ready for delivery. Flight Software and Avionics have been delivered and are in integration testing. In November 1999, the first graphite composite liquid hydrogen tank experienced a debond between the tank inner skin and the honeycomb core in testing. This tank had completed its third successful cryogenic and loads testing at MSFC. Replacement liquid hydrogen tanks have completed design and are in fabrication. The resulting delay from this change of design for the liquid hydrogen tank will be approximately two years.

Austin, Robert E.↗

22 N HPGP Thruster Life Testing

In the ever-changing paradigm of efficient and capable spacecraft design, scientific missions continue pushing the envelope enabling spacecraft subsystems to deliver effective solutions to meet challenging new mission/spacecraft needs. From an in-space storable liquid chemical propulsion perspective, monopropellant hydrazine has been, and continues to be, a dependable propellant with considerable flight heritage, a variety of engine thrust classes available from multiple vendors, with repeatable and reliable performance. Additionally, the space propulsion industry has learned to successfully handle hydrazine, its regulations, the safety protocols, the personnel protective equipment, and the unique training standards–all requisite for loading spacecraft propulsion systems with toxic hypergolic hydrazine. The question now arises as to “what is next for in-space chemical propulsion?” Further, with the evolution and concrete advancements in innovative in-space green propellant technologies, capable of providing realizable benefits to scientific missions, concern over the reliability and availability of this higher performing and safer to handle class of propellants is waning. As science missions move forward with the potential flight in fusion of High Performance Green Propulsion (HPGP), NASA and its industry partners are working to address any gaps in system reliability, performance, or unique operational considerations. Propellant technology that offers both higher performance and significant reduction in personnel hazards compared to hydrazine presents an attractive propulsion subsystem design opportunity. Increased propulsion subsystem performance can result in lower spacecraft launch mass, larger scientific payloads, or extended on-orbit lifetimes. Mission trades using green propulsion technologies have been documented on multiple NASA Goddard Space Flight Center (GSFC) mission classes, examining various parameters and requirements to support mission architectures in Low Earth Orbit (LEO), High Earth Orbit (HEO), geostationary, lunar, planetary, and Quasi-halo orbit around Sun-Earth Lagrange point (L2). The results of these trade studies show promising, attainable benefits. The perceived programmatic risk of flying a newer propulsion technology has, unfortunately, not outweighed the benefits to date. To take advantage of the improved performance and mitigate programmatic risk, HPGP engines must demonstrate life testing at higher propellant throughputs than have currently been demonstrated. In an effort to proactively address the challenges with technology infusion into a risk-averse community, NASA and the Swedish National Space Agency (SNSA) outlined a collaborative Implementing Arrangement (IA) for the respective agencies to pursue increased HPGP technology maturation. This initial IA effort began in 2013, fresh off the heels of the successful PRISMA HPGP technology demonstration mission. The IA targeted objective is to reduce risk to potential future HPGP missions and fully characterize the LMP-103S propellant and associated engine performance. Over the past eight years, HPGP has flown in propulsion systems on twenty-five(25) spacecraft from seven(7) different Launch Ranges around the globe and on seven (7) different Launch Vehicles. Six(6) of these launches involved multiple loading operations for multiple spacecraft. For U.S. Range operations, nine (9) HPGP systems have been processed at Vandenberg Space Force Base(VSFB):six(6) in 2017, and three (3) in 2018. Six (6) more have been processed at Cape Canaveral Air Force Station (CCAFS)in May 2020, with three (3) systems launched in June 2020 and the remaining three (3) system were left loaded and ready until their launch in August of 2020. Three (3) more systems have been processed at Wallops Flight Facility(WFF)and launched in June 2021. In addition, these propulsion subsystems employed heritage propulsion subsystem component such as valves, filters, and pressure transducers, and have further demonstrated nominal functionality in both diaphragm and Propellant Management Device (PDM) propellant tanks. Based on these successes, HPGP technology continues to be considered for NASA Science Mission Directorate missions at GSFC. The work presented herein represents many years of development and collaborative efforts to successfully align higher performance, low toxicity hydrazine alternatives into scientific missions. NASA GSFC Propulsion Engineering, in collaboration with Bradford ECAPS, has developed mission specific thruster design and testing requirements to establish GSFC’s desired test conditions and firing sequences.In2017, the first flight-like 22N HPGP thruster Engineering Qualification Model (EQM-1)was designed and built by Bradford ECAPS to prove out the thruster design, materials, build process, and test campaign with respect to NASA GSFC critical component and mission requirements. This test program was developed to comprehensively test the thruster, the technology, and ultimately increase the 22N HPGP Technology Readiness Level(TRL). EQM-1was tested to environmental qualification levels prior to hot fire performance testing to represent the relevant end-to-end environment (launch to on-orbit operation)with required margin. This thruster demonstrated steady-state and pulse mode operational capability with propellant thruster throughput up to~53kg.At this throughput level, the EQM-1 engine began to present off-nominal performance and the test campaign was halted to allow for non-destructive testing and identify the root cause for the an omalous performance. Capitalizing on the successful elements of the EQM-1 campaign, an upgraded 22N HPGP EQM-2 has been manufactured by Bradford ECAPS to meet the complete GSFC requirements. The EQM-2 thruster’s test campaign has further demonstrated the robustness of the HPGP propulsion technology and increased the Technology Readiness Level (TRL) by undergoing a full acceptance test program, then proceeding into qualification, including environmental testing (vibration and shock to qualification levels),as well as hot-fire life testing, operating at steady-state and pulse modes with increased propellant thruster throughput to~150kg. The HPGP thruster performance testing enables effective HPGP thruster readiness evaluation to meet NASA candidate mission requirements in the future.

High↗

Towards standardized nuclear reactors: Seismic isolation and the cost impact of the earthquake load case

We report nuclear energy has a key role to play in global decarbonization. Impediments to the widespread deployment of reactors are their projected high capital cost and levelized cost of energy, and time required to analyze, design, license, construct, and commission them. The earthquake load case is a key cost driver for a new build nuclear plant, because near-surface soils and seismic hazard are different at each site, requiring site-specific analysis, design, engineering, qualification, licensing, and regulatory review, essentially making every design First-of-a-Kind (FoaK). To enable deployment at the scale needed for deep decarbonization, the cost and time impact of the seismic load case must be significantly mitigated, and plants must be standardized. Seismic base isolation has been proven to considerably reduce the earthquake response of structures and equipment but has yet to be applied to a nuclear power plant in the United States, in part because the financial impacts, positive or negative, are not known. Because there are no recent non-proprietary data to characterize the influence of the seismic load case on capital cost, it is difficult to confidently quantify the financial benefits of seismic isolation. Scheme-level designs of two fundamentally different advanced reactor buildings were developed to assemble cost data on the influence of the seismic load case. Both buildings were equipped with three bespoke pieces of safety-related equipment and analyzed for incremented levels of earthquake shaking to quantify the seismic penalty on equipment, in terms of vessel weights and horizontal accelerations. Using analysis results, a questionnaire was developed and transmitted to nuclear utilities, reactor developers, engineers, and equipment suppliers to collect cost data on engineering and fabrication costs for these unique pieces of safety-class equipment. Synthesis of the cost data showed that the seismic load case significantly affects the capital cost (sum of engineering and fabrication cost) of safety-class equipment, with engineering costs being comparable to fabrication costs. Standardization of safety-class equipment is made possible by seismic isolation, that is, equipment designed for minimal seismic robustness can resist earthquake shaking at a site of much higher seismic hazard. The average reduction in the capital cost of the safety-related equipment, enabled by seismic isolation, is a factor of two for FoaK equipment and a factor of five for standardized equipment.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Apollo reaction control systems.

Apollo reaction control systems, describing command module, service module, lunar module, engine qualifications, etc

Vaughan, C. A.↗

Design, fabrication, testing, and delivery of improved beam steering devices

The development, manufacture, and testing of an optical steerer intended for use in spaceborne optical radar systems are described. Included are design principles and design modifications made to harden the device against launch and space environments, the quality program and procedures developed to insure consistent product quality throughout the manufacturing phase, and engineering qualification model testing and evaluation. The delivered hardware design is considered conditionally qualified pending action on further recommended design modifications.

Source record↗

Apollo quality through predictive testing.

Discussion of testing performed during the Apollo program and its relationship to the engineering, qualification, manufacturing, maintenance, and training aspects of the program. Illustrative examples of Apollo experience are used to highlight the discussion.

White, G. C., Jr.↗

Synthetic Organic Materials in Nuclear Powerplants

Report aids plant designers and qualification engineers in ensuring that organic materials in nuclear powerplants will perform satisfactorily in such safety-related equipment as insulation on motor windings, pump diaphragms, motor and pump lubricants, and pump seals and gaskets. Report provides information for service that may include both mild and harsh nuclear environments.

Bouquet, F. L.↗

Rover/NERVA-derived near-term nuclear propulsion

FY-92 accomplishments centered on conceptual design and analyses for 25, 50, and 75 K engines with emphasis on the 50 K engine. During the first period of performance, flow and energy balances were prepared for each of these configurations and thrust-to-weight values were estimated. A review of fuel technology and key data from the Rover/NERVA program established a baseline for proven reactor performance and areas of enhancement to meet near-term goals. Studies were performed of the criticality and temperature profiles for probable fuel and moderator loadings for the three engine sizes, with a more detailed analysis of the 50 K size. During the second period of performance, analyses of the 50 K engine continued. A chamber/nozzle contour was selected and heat transfer and fatigue analyses were performed for likely construction materials. Reactor analyses were performed to determine component radiation heating rates, reactor radiation fields, water immersion poisoning requirements, temperature limits for restartability, and a tie-tube thermal analysis. Finally, a brief assessment of key enabling technologies was made, with a view toward identifying development issues and identification of the critical path toward achieving engine qualification within 10 years.

Source record↗

Cassini radar: Instrument description and performance status

The spacecraft of the Cassini mission is planned to be launched towards Saturn in October 1997. The mission is designed to study the physical structure and chemical composition of Titan. The results of the tests performed on the Cassini radar engineering qualification model (EQM) are summarized. The approach followed in the verification and evaluation of the performance of the radio frequency subsystem EQM is presented. The results show that the instrument satisfies the most relevant mission requirements.

Johnson, W. T. K.↗