Hydrogen pressure cycling of subscale pipes to simulate full-scale testing of transmission pipelines
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San Marchi, Christopher William↗
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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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Full-Scale Testing of Underwater Obscurant at Sandia?s Gamma Irradiation Facility (GIF).
Abstract not provided.
Thompson, Andrew↗
HYDROGEN PRESSURE CYLCING OF SUBSCALE PIPES TO SIMULATE FULL-SCALE TESTING OF TRANSMISSION PIPELINES (IPC2024-134173)
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San Marchi, Christopher William↗
Considerations for testing full-scale wind turbine nacelles with hardware-in-the-loop
In this paper, pole placement control techniques are utilized to compensate for variations in the torsional dynamics resulting from the different boundary conditions experienced by a wind turbine nacelle when mounted on a test bench. Simulation case studies are used to understand the baseline torsional characteristics of the nacelle coupled to the test bench versus that coupled to the rotor. It was found that the frequency shifts by up to 200% and 400% for the first and second torsional modes, respectively. The feasibility of utilizing pole placement technique to match the torsional characteristics of the turbine on the test bench is investigated using PI and PID controllers. Here, the performance of the tuned controller is then verified under two test scenarios: Low Voltage Ride Through (LVRT), and a highly dynamic turbulent wind input. It is demonstrated that tuning the test bench speed controller can effectively shift the poles of the closed-loop system to match the desired first and second modes of the full turbine and replicate transient field events on the test bench.
17 WIND ENERGY↗
Effects of Coatings on Water Intrusion and Strain Gauge Durability in Submerged Fatigue Conditions: Preprint
Marine energy structures are typically made using composite materials and are repeatedly loaded by currents and waves. Submersion and repeated loading lead to two environmental effects: moisture intrusion and mechanical fatigue. To understand the combined effects of moisture intrusion and mechanical fatigue on marine energy structures, submerged fatigue testing can be used. Submerged fatigue testing often requires submerged instrumentation to validate component manufacturing methods and models. Measuring strain is critical for understanding marine energy component loads. One common method for measuring strain is by using foil strain gauges, but the durability of strain gauges in submerged fatigue conditions was not well-understood. To increase strain gauge durability and protection from contamination, delamination, and water intrusion, strain gauge coatings may be applied over strain gauges and wire connections. In this study, strain gauges were adhered to composite coupons, coated, and mechanically tested in a water tank. Cycles to composite failure, cycles to strain gauge failure, strains, and strain gauge failure modes were used to measure the effects of strain gauge coatings on composite fatigue life and strain gauge durability. The methods developed and measurements taken at the coupon scale in this study will be used to inform methods and designs for subsequent submerged subcomponent testing, full-scale testing, and standards development. The benefits of designing marine energy structures to informed standards and designs are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.
composite fatigue testing↗
Effects of Strain Gauge Coatings on Water Intrusion in Submerged Composite Coupon Testing
Marine energy structures are typically made using composite materials and are repeatedly loaded by currents and waves. Submersion and repeated loading lead to two environmental effects: moisture intrusion and mechanical fatigue. To understand their combined effects, submerged fatigue testing can be used. Submerged fatigue testing often requires submerged instrumentation to validate component manufacturing methods and models. Strain measurements are critical for understanding marine energy component loads. One common method for measuring strain is by using foil strain gauges, but the durability of strain gauges in submerged fatigue conditions is not well-understood. To increase strain gauge durability and protection from contamination, delamination, and water intrusion, strain gauge coatings may be applied over strain gauges and wire connections. In this study, strain gauges were adhered to composite coupons, coated, and mechanically tested in a water tank. Cycles to composite failure, cycles to strain gauge failure (SGF), strains, and SGF modes were used to measure the effects of strain gauge coatings on composite fatigue life and strain gauge durability. The coatings did not have significant effects on composite fatigue life or strain gauge durability. The methods developed and measurements taken at the coupon scale in this study will be used to inform methods and designs for subsequent submerged subcomponent testing, full-scale testing, and standards development. The benefits of designing marine energy structures to informed standards and designs are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.
composite materials↗
Scaling for Nuclear Reactor System: Overview
A scaling analysis is essential for predicting the behavior of a reactor system under various operating conditions, as well as for ensuring safe and reliable experimentation and adequate dataset generation for supporting the system code model development and assessment in accordance with USNRC guidelines 1.203. Testing and modeling can be carried out at various scales, from small test units to full-scale reactors, to validate the predictions produced by the analysis. However, due to the cost and challenges associated with full-scale testing, the nuclear industry uses scaled test facilities—integral effect test (IET) and separate effect test (SET)—to identify potential design issues and optimize the design to ensure regulatory compliance for safer operation and anticipated accident management. In general, IET facilities are non-nuclear thermal hydraulics test facilities. In contrast, SET facilities can be non-nuclear testing (e.g., steam generator, containment, pump system SETs) and nuclear testing (mostly fuel-material irradiation testing). IETs are used to study the system-level thermal-hydraulic behavior of the reactor coolant system (RCS) under different anticipated operational occurrences (AOOs) and design basis accidents (DBAs) such as loss-of-coolant-accident (LOCA) and loss-of-power (i.e., station blackout) and loss-of-flow (i.e., failure of RCS pump). Several LOCA scenarios could happen in reactor DBAs, such as main steam line break (MSLB), SG tube rapture (SGTR), break in direct vessel injection (DVI), and other small breaks LOCA. Scaling analysis determines the appropriate size and operating conditions for the test facility. This involves analyzing the system's thermal-hydraulic behavior at different scales and identifying the key parameters that affect the thermal-hydraulic behavior of the reactor. These key parameters can be identified so that the scaled facility can replicate the expected conditions in a prototypical setting. The scaled facility can simulate the same flow rates, pressure gradients, heat transfer coefficients, and fluid properties as the prototype. Scaling analysis is used to ensure that the results from these tests can be scaled up to predict the behavior of a full-scale prototype with an acceptable range of scaling distortions.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Large-scale inflatable structures for tunnel protection: a review of the Resilient Tunnel Plug project
The protection of underground civil infrastructure continues to be a high priority for transportation and transit security agencies. In particular, rail transit tunnels running under bodies of water are susceptible to disruptions due to flooding caused by extraordinary climatic events such as hurricanes or other events resulting from human activities. Several events have taken place in the past decades that have demonstrated the need to mitigate vulnerabilities or, at least, minimize the consequences of catastrophic events. Although it is impossible to prevent all situations that can lead to flooding, damage can be substantially decreased by reducing the area affected by the event. To minimize the effects of an event, a possible approach is to compartmentalize the tunnel system by creating temporary barriers that can contain the propagation of flooding until a more permanent solution can be implemented. One way to create a temporary barrier is by the deployment of a large-scale inflatable structure, also known as an inflatable plug. In such an application, the inflatable structure is prepared for placement, either permanently or temporally, and maintained ready for deployment, inflation, and pressurization when needed. The internal plug pressure imparts a normal force against the tunnel wall surface with the friction between the plug and tunnel surfaces opposing axial movement of the plug. The sealing effectiveness depends on the ability of the inflatable structure to self-deploy and fit, without human intervention, to the intricacies of the perimeter of the conduit being sealed. Primary design constraints include having the plug stowed away from the dynamic envelope of the trains and being able to withhold the pressure of the flooding water. This work presents a compilation of the main aspects of the activities completed for the development of large-scale inflatable structures as part of the Resilient Tunnel Plug (RTP) Project. The main test results and lessons learned are presented to demonstrate the viability of implementing large-scale inflatable plugs for the containment of flooding in rail tunnels systems. Over 400 coupon and specimen tests, 200 reduced scale tests, and 100 full-scale tests were conducted to demonstrate the efficacy of the design of different prototypes over a 10-year research and development project. The culmination of the work was 12 large-scale flooding demonstrations where the inflatable tunnel plug was shown able to be deployed remotely and withstand a simulated flooding event.
42 ENGINEERING↗
Development of a Pipe Crawler Inspection Tool for Fossil Energy Power Plants
This document presents the final report of the research activity completed during the four years of the project and includes the major challenges and accomplishments. The report presents specific details of the engineering processes and methodologies used to develop the robotic crawler and complete the project milestones. In particular, the report includes sections that address the problem statement, background, development of crawler modules, bench scale testing, simulation development and full scale testing. The report concludes with a discussion on potential paths forward and concluding remarks.
20 FOSSIL-FUELED POWER PLANTS↗
Get your own commemorative poster of the nation’s last full-scale weapons test ‘Divider’ marks its 30th anniversary, Lab’s pivot to stockpile stewardship
This report provides basic information about Divider, the nation's last full-scale weapons test and how to get a commemorative poster marking the 30th anniversary.
45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
Full-scale validation gaps and opportunities for low-head hydropower: a review and perspective
Hydropower is undergoing technological innovation as future development increasingly targets low-head sites (<10 m), primarily through retrofits, rehabilitation, and upgrades of existing infrastructure. This shift toward smaller systems creates a timely opportunity: unlike conventional large projects, many emerging low-head technologies may be small enough for direct full-scale validation. Full-scale testing is particularly important for environmental mitigation technologies, including fish passage, sediment continuity, and water-quality improvements, whose performance is difficult to assess reliably using reduced-scale models. Yet adoption remains constrained by the limited risk-bearing capacity of small hydropower owners, discouraging manufacturers from bringing unvalidated technologies to market. This review and perspective paper examines hydropower trends driving innovation, selected emerging technologies, conventional testing methods, and current U.S. testing capabilities as a case study. We then evaluate the gap between existing capabilities and the needs of low-head powertrains and environmental mitigation measures. Many technologies exceed existing facility flow capacities; in the U.S., the highest combined head–flow capability is limited to 5.66 m3/s, compared with median and 90th-percentile low-head turbine-unit flows of 14.3 and 60 m3/s. To mitigate this gap, we advocate repurposing large, retired, or underused hydraulic infrastructure as full-scale testing facilities to reduce first-adoption risk and support sustainable low-head hydropower deployment.
Tseng, Chien-Yung [Colorado State University, Fort↗
Posiva's Onkalo{sup R} FST (Full-Scale In Situ System Test) - 20051
The FST - Full-scale In Situ System Test - is a unique full-scale demonstration of disposal system in crystalline host rock. The FST was constructed in ONKALO{sup R} demonstration area at the disposal depth of 420 metres, in Posiva's actual final disposal facility at Olkiluoto, Finland. The demonstration has included design, manufacture, installation and comprehensive instrumentation for monitoring the evolution of the disposal system and its components. The demonstration tunnel and experimental deposition holes were excavated in 2010 in ONKALO to address that they can be excavated to meet the requirements set for them. Two experimental deposition holes, bored in the floor of the tunnel, host each a canister surrounded by bentonite clay buffer rings/segments in the holes. Inside the canisters are heating elements to simulate decay heat emitted by spent fuel. The tunnel part used for the test is about 50 m long and it was filled with bentonite clay backfill after the installation of the canisters and buffer components. The tunnel is closed with a steel-reinforced concrete plug. The test is equipped with 500 sensors to monitor early evolution of the system. To forecast the evolution of the system, a mathematical model has been created. (authors)
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Wave Tank Testing Report for Controls Validation of a Heaving Point Absorber
The core objectives of this project is to improve the power capture of three different wave energy conversion (WEC) devices by more than 50% using an advanced control system and validate the attained improvements using wave tank and full scale testing. In parallel, we will bring along the development of a wave prediction system that is required to enable effective control and test it at full scale. The purposes of this report are to: 1. Plan and document the 1/25th scale device testing at the wave-tank facility; 2. Document the test article, setup and methodology, sensor and instrumentation, mooring, electronics, wiring, and data flow and quality assurance; 3. Communicate the testing results between the associated members; 4. Facilitate reviews that will help to ensure all aspects (risk, safety, testing procedures, etc.); 5. Provide a systematic guide to setting up, executing and decommissioning the experiment.
16 TIDAL AND WAVE POWER↗
Evaluation of dynamic testing of full-scale wind turbine drivetrains with hardware-in-the-loop
Dynamometer testing of full-scale wind turbine drivetrains involves subjecting integrated components to extreme static loads, fatigue loads, or dynamic loads to replicate field conditions. This paper provides a detailed evaluation of the uncertainty and errors in applied loads and measured responses, and their magnitude relative to established repeatability bounds for a drivetrain subjected to static and dynamic loads on the 7.5 MW test bench at the Clemson University Wind Turbine Drivetrain Testing Facility. An ideal drivetrain simulation model is utilized to isolate the influence of load tracking errors on test article responses. It is shown that the test article response variations are mainly driven by run out and clearances inherent to the drivetrain. For the dynamic profiles, the load tracking errors are within acceptable limits. Furthermore, a frequency analysis is used to show that the test bench controller tracking performance is acceptable for profiles with frequency content up to 1.5 Hz.
17 WIND ENERGY↗
Virtual and Augmented Realities to Support Development, Training, Deployment, and Operations of Remote Systems - 20516
Throughout the U.S. Department of Energy complex, there is a need to deploy new, unique equipment and systems for cleanup activities, waste processing, infrastructure repair, and decommissioning and demolition in radioactive and hazardous environments. The new equipment often consists of custom systems created by integrating and modifying commercial technologies. In addition, the systems are deployed in unique environments due to limited access, waste properties, and the presence of previously installed equipment or infrastructure that has been left in place. The deployment of custom systems that are 'turnkey' ready for first-time installation and application has its risks. Use of test platforms and mockups for cold (i.e., non-radioactive) testing is one method to mitigate that risk: however, full-scale test mockups for operations such as waste retrieval and tank inspection can be expensive and must be modified to incorporate the uniqueness of each application. An alternative to full-scale mockups is to use three-dimensional (3D) virtual environments and virtual reality (VR) technology to develop interactive virtual test beds. These can be used throughout the down-selection, development, system integration, operational planning, operator training, and mission execution phases of a task. Virtual test beds are readily reconfigured, can be used for multiple tasks, support multiple users in parallel, and can accommodate enhancements and changes not originally planned or conceived in the initial design. Virtual test beds also provide a platform for developing and testing augmented reality (AR) tools for improving operator efficiency. A VR experience has been generated for waste retrieval from a Hanford waste tank to present the potential applications of a virtual test bed. Features of the VR experience are presented, potential applications of VR and AR for remote applications are discussed, and development areas for improving future application are considered. (authors)
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Predicting Asteroid Material Properties from a DART-like Kinetic Impact
Abstract NASA’s Double Asteroid Redirection Test (DART) mission is the first full-scale test of the kinetic impactor method for asteroid deflection, in which a spacecraft intentionally impacts an asteroid to change its trajectory. DART represents an important first step for planetary defense technology demonstration, providing a realistic assessment of the effectiveness of the kinetic impact approach on a near-Earth asteroid. The momentum imparted to the asteroid is transferred from the impacting spacecraft and enhanced by the momentum of material ejected from the impact site. However, the magnitude of the ejecta contribution is dependent on the material properties of the target. These properties, such as strength and shear modulus, are unknown for the DART target asteroid, Dimorphos, as well as most asteroids since such properties are difficult to characterize remotely. This study examines how hydrocode simulations can be used to estimate material properties from information available post-impact, specifically the asteroid size and shape, the velocity and properties of the impacting spacecraft, and the final velocity change imparted to the asteroid. Across >300 three-dimensional simulations varying seven material parameters describing the asteroid, we found many combinations of properties could reproduce a particular asteroid velocity. Additional observations, such as asteroid mass or crater size, are required to further constrain properties like asteroid strength or outcomes like the momentum enhancement provided by impact ejecta. Our results demonstrate the vital importance of having as much knowledge as possible prior to an impact mission, with key material parameters being the asteroid’s mass, porosity, strength, and elastic properties.
79 ASTRONOMY AND ASTROPHYSICS↗
Advanced Multi-Tube Mixer Combustion for 65% Efficiency (Final Report)
This project targeted advanced low NOx combustion for advanced gas turbines capable of 65%, or greater, efficiency in combined cycle application. This technology advancement has further potential to benefit gas turbines used in coal based IGCC applications with pre-combustion carbon capture and hydrogen as the resulting fuel. The program developed and synthesized the most advanced combustion system capable of achieving low NOX emissions up to turbine inlet temperatures of 3100F while also supporting the load-following needs of a modern grid. The combustion system contributes to the overall gas turbine efficiency goal by setting the maximum cycle temperature achievable for a given NOX level and by minimizing the through-combustor air flow pressure drop. Focus areas for this project targeted maximizing the turbine inlet temperature entitlement, as constrained by emissions considerations. The design also minimized parasitic air flow pressure drop by using advanced cooling techniques and performance materials selections and by minimizing hot surface area. These two technology objectives (maximum, emissions-compliant cycle temperature and minimum air flow pressure drop) were integrated into a prototype design. The primarily analytical project sought to identify the most promising technologies to meet these objectives. Additional critical “jugular” data were obtained from multi-tube mixer tests to realize the potential of leveraging “micro flames” for minimizing overall hot surface area. This data was used, in conjunction with an understanding of advanced material and cooling design technologies, to analytically develop multiple design concepts. Phase I focused on in-depth engineering analysis and design, with minimal supporting laboratory testing to enable a selection of the top three combustion architectures for achieving these overall objectives. Phase II of the program developed the selected design through a combination of sub-scale testing and analytical efforts. Early tests included a cold-flow cascade to establish aerodynamic performance characteristics and a sub-scale fired test at GE Global Research in Niskayuna, NY, to establish cooling and heat transfer characteristics in conjunction with combustion performance. The data from these tests validated the analytical models to ultimately design a full-scale, test article to evaluate at prototypical pressure and temperature conditions at GE Gas Power’s Gas Turbine Technology Laboratory in Greenville, SC. GE Gas Power also developed, tested, and recommended a suitable seal design to be applied to the unique features of the combustor. To assess the technology challenges from prospective future production of the combustor from a ceramic matrix composite material, screening tests of Environmental Barrier Coatings were completed.
20 FOSSIL-FUELED POWER PLANTS↗