Flaw Sizing Techniques for GWPA Inspection of DST Primary Liner Floors
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11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
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NDE Technology Development Program for Non-Visual Volumetric Inspection Technology; Sensor Effectiveness Testing Report
The Pacific Northwest National Laboratory (PNNL) located in Richland, Washington, hosted and administered Sensor Effectiveness Testing that allowed four different participants to demonstrate the NDE volumetric inspection technologies that were previously demonstrated during the Technology Screening session. This document provides a Sensor Effectiveness Testing report for the final part of Phase I of a three-phase NDE Technology Development Program designed to identify and mature a system or set of non-visual volumetric NDE technologies for Hanford DST primary liner bottom inspection. Phase I of the program will baseline the performance of current or emerging non-visual volumetric NDE technologies for their ability to detect and characterize primary liner bottom flaws, and identify candidate technologies for adaptation and maturation for Phase II of the program.
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Development of Robotic Crawlers for Inspection of Radioactive Waste Tanks and Transfer Lines - 19573
The leaks in the primary liner of Double Shell Tank (DST) 241-AY-102 have motivated a number of research efforts to develop inspection tools that can obtain information regarding the integrity of the Hanford DSTs. Recently, there have been additional concerns regarding the DST secondary liners as well various pipelines within the waste transfer system. Over the past few years, Florida International University (FIU) has developed a pneumatic pipe crawler that can navigate through 3- and 4-inch diameter pipes and provide visual feedback while traveling through pipelines in excess of 100 feet and multiple 90 degree elbows. Recent updates to the crawler include a new sensor module that can provide information regarding environmental conditions within the pipeline and a mapping of the interior surface of the line. The sensor module is a carousel type device that can rotate 360 degrees and is placed near the front of the 3- and 4- inch crawler. The module can house a number of sensors including temperature, pressure, radiation, Lidar, optical camera and an inertial measurement unit (IMU). The intent of the module is to improve the functionality of the crawler by providing environmental conditions within the pipe and internal surface topography maps that can assist in understanding potential wear, pitting or thinning of the pipe. In addition to the 3- and 4-inch crawler, FIU is developing a 6-inch crawler that utilizes the same principles as the smaller unit. The objective of this tool is to navigate through the 6-inch drain lines leading to the drain channels within the foundation underneath the secondary liner of the DSTs. This crawler will house a miniature rover that will be deployed at the end of the drain pipe, where it connects to the foundation. The miniature rover will operate upside down, via magnets, underneath the secondary liner within the drain slots and provide visual information regarding the condition of the secondary liner. Thinning of the secondary liner has been noted from the annulus of the some of the DSTs, but it is unclear if the thinning is isolated to locations near the annulus. (authors)
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Development of a Semi-autonomous Miniature Rover for Inspection of Double Shell Tank Floors - 19575
Leaks in the primary liner of double-shell tank (DST) 241-AY-102 at Hanford have prompted the need for the development of inspection tools that are able to access confined spaces around and underneath the tanks. Last year, Florida International University (FIU) has continued to improve inspection tools that were developed in the previous years, to ensure that the resultant tools are able to overcome the challenges posed by the DSTs. Experimental testing conducted last year at the full-scale sectional mock-up of the DST's refractory slots revealed some shortcomings of the miniature rover, particularly in traversing over weld seams of different heights. The weld seams are the results of welded steel plate-joints for the DST. It was advised by the site engineers that the weld seams height could range from 6.35 mm - 9.525 mm (1/4 to 3/8 inches), and with 12.7 mm (1/2 inches) width. As the rover traverses over a weld seam, the gap between the rover's magnets and tank surface increases, causing the adhesive force to drop. The rover loses its surface contact if this adhesive force drops below its weight, jeopardizing the inspection tasks. In this paper, we present the numerical studies to calculate the minimum magnetic force required for the miniature rover to traverse over weld seams with different heights and the corresponding modifications to the rover design. Initial bench scale tests were conducted using a steel bar with 5 welds of varying heights. The testing validated the results from the simulation studies and established the rover's capability in traversing weld seams. Another challenge for the miniature rover is the use of a joystick or keypad for manual control. Utilizing these controls will likely be difficult for the operators due to the tight channels underneath the tank. Having a semi-autonomous navigational capability would alleviate the complexity of the inspection tasks and allow the operator to focus on the channel inspection. The goal is to implement lane-keeping capability, akin to that of a driverless car, for the inspection tool, so that it will maintain its relative position with respect to the wall of the channels. Am image processing pipeline has been developed using both the Robot Operating System (ROS) and OpenCV to process the image stream coming from the onboard camera, for the purpose of lane identification. Additionally, a PID controller has been implemented to navigate the miniature rover along the central location of the detected lane, while allowing the operator to control the tool's forward and backward motion. (authors)
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Comparison of primary zone combustor liner wall temperatures with calculated predictions
Calculated liner temperatures based on a steady-state radiative and convective heat balance at the liner wall were compared with experimental values. Calculated liner temperatures were approximately 8 percent higher than experimental values. A radiometer was used to experimentally determine values of flame temperature and flame emissivity. Film cooling effectiveness was calculated from an empirical turbulent mixing expression assuming a turbulent mixing level of 2 percent. Liner wall temperatures were measured in a rectangular combustor segment 6 by 12 in. and tested at pressures up to 26.7 atm and inlet temperatures up to 922 K.
Norgren, C. T.↗
Explanation of Anomalous Behavior Observed in Impedance Eduction Techniques Using Measured Data
Several enhancements that improve the accuracy and robustness of an impedance eduction technique that use an automatic optimizer are presented. These enhancements are then used to launch an intensive investigation into the cause of anomalous behavior that occurs for a small number of test conditions. This anomalous behavior is investigated for both a hardwall insert and a conventional liner. The primary conclusions of the study are that: (1) for the hard wall insert, the anomalies are due to narrow peaks in the objective function, (2) For the conventional liner, the anomalies are due to the presence of an extremely flat objective function, and (3) the anomalies appear to be triggered by inconsistencies between the duct propagation model and the measured data. At high frequencies, the duct propagation model may need to include the effects of higher-order duct modes, whereas at low frequencies, the effects of the mean boundary layer may have to be included.
Watson, Willie R.↗
NDE Technology Development Program for Non-Visual Volumetric Inspection Technology - Phase I Summary Report
This report provides a summary of the outcomes and findings of the sensor testing and evaluation work performed in FY2017 and first quarter of FY2018 under Phase I of the NDE Technology Development Program. The objective of this summary report is to provide a condensed version of the information provided in the Phase I program plan, Phase I test plan, the two comprehensive Phase I interim test reports issued for Technology Screening and advanced Sensor Effectiveness Testing, and the results from testing and demonstrations conducted Post-Sensor Effectiveness Testing for the purpose of supporting the selection of sensor technologies for maturation under Phase II. The orthogonal research and planning that should accompany technology maturation to support Phase II and Phase III are also included. The full details of the test mock-ups and flaws, sensor technologies, tests, evaluation criteria, and evaluation results are included in Phase I and provided in the interim Phase I test reports on Technology Screening and Sensor Effectiveness Testing.
47 OTHER INSTRUMENTATION↗
NDE Technology Development Program for Hanford DST Non-Visual Volumetric Inspection Technology – Phase II; Technical Letter Report on Air-slot NDE Sensor Maturation Testing
The Pacific Northwest National Laboratory (PNNL) located in Richland, Washington, hosted and administered Phase II Flaw Detection Performance Tests in August 2018 that allowed the newly matured ultrasonic guided wave phased-array (GWPA) air-slot NDE sensor—“Hanford-Probe A”—developed by Guidedwave to be evaluated for its flaw detection capability and repeatability. A portion of the Phase II Flaw Detection Performance Tests was performed on a subset of test flaws on which the original GWPA sensor was evaluated during Phase I Sensor Effectiveness Testing (SET) to facilitate a comparison in flaw detection performance between Hanford-Probe A and the original GWPA sensor demonstrated in Phase I. The objective of the performance comparison was to determine the extent to which GWPA sensor design changes impacted the flaw detection performance upon which selection of the sensor technology was originally based for the purpose of determining whether the flaw detection performance of the newly matured Hanford-Probe A GWPA air-slot NDE sensor is at least equal to that of the original GWPA sensor evaluated under Phase I SET. This technical letter report presents the results produced by the new Hanford-Probe A on the Phase I test flaws and the results of the flaw detection performance comparison between Hanford-Probe A and the original GWPA sensor demonstrated in Phase I.
47 OTHER INSTRUMENTATION↗
Effect of fuel vapor concentrations on combustor emissions and performance
Effects of fuel vaporization on the exhaust emission levels of oxides of nitrogen, carbon monoxide, total hydrocarbons, and smoke number were obtained in an experimental turbojet combustor segment. Two different fuel injectors were used in which liquid ASTM A-1 jet fuel and vapor propane fuel were independently controlled to simulate varying degrees of vaporization. Tests were conducted over a range of inlet-air temperatures from 478 to 700 K, pressures from 4 to 20 atm, and combustor reference velocities from 15.3 to 27.4 m/sec. Converting from liquid to complete vapor fuel resulted in oxides of nitrogen reductions of as much as 22 percent and smoke number reductions up to 51 percent. Supplement data are also presented on flame emissivity, flame temperature, and primary-zone liner wall temperatures.
Norgren, C. T.↗
ERBS fuel addendum: Pollution reduction technology program small jet aircraft engines, phase 3
A Model TFE731-2 engine with a low emission, variable geometry combustion system was tested to compare the effects of operating the engine on Commercial Jet-A aviation turbine fuel and experimental referee broad specification (ERBS) fuels. Low power emission levels were essentially identical while the high power NOx emission indexes were approximately 15% lower with the EBRS fuel. The exhaust smoke number was approximately 50% higher with ERBS at the takeoff thrust setting; however, both values were still below the EPA limit of 40 for the Model TFE731 engine. Primary zone liner wall temperature ran an average of 25 K higher with ERBS fuel than with Jet-A. The possible adoption of broadened proprties fuels for gas turbine applications is suggested.
Bruce, T. W.↗
Critical research and advanced technology (CRT) support project
A critical technology base for utility and industrial gas turbines by planning the use of coal-derived fuels was studied. Development tasks were included in the following areas: (1) Combustion - investigate the combustion of coal-derived fuels and methods to minimize the conversion of fuel-bound nitrogen to NOx; (2) materials - understand and minimize hot corrosion; (3) system studies - integrate and focus the technological efforts. A literature survey of coal-derived fuels was completed and a NOx emissions model was developed. Flametube tests of a two-stage (rich-lean) combustor defined optimum equivalence ratios for minimizing NOx emissions. Sector combustor tests demonstrated variable air control to optimize equivalence ratios over a wide load range and steam cooling of the primary zone liner. The catalytic combustion of coal-derived fuels was demonstrated. The combustion of coal-derived gases is very promising. A hot-corrosion life prediction model was formulated and verified with laboratory testing of doped fuels. Fuel additives to control sulfur corrosion were studied. The intermittent application of barium proved effective. Advanced thermal barrier coatings were developed and tested. Coating failure modes were identified and new material formulations and fabrication parameters were specified. System studies in support of the thermal barrier coating development were accomplished.
Furman, E. R.↗
A variable-geometry combustor used to study primary and secondary zone stoichiometry
A combustion program is underway to evaluate fuel quality effects on gas turbine combustors. A rich-lean variable geometry combustor design was chosen to evaluate fuel quality effects over a wide range of primary and secondary zone equivalence ratios at simulated engine operating conditions. The first task of this effort, was to evaluate the performance of the variable geometry combustor. The combustor incorporates three stations of variable geometry to control primary and secondary zone equivalence ratio and overall pressure loss. Geometry changes could be made while a test was in progress through the use of remote control actuators. The primary zone liner was water cooled to eliminate the concern of liner durability. Emissions and performance data were obtained at simulated engine conditions of 80 percent and full power. Inlet air temperature varied from 611 to 665K, inlet total pressure varied from 1.02 to 1.24 MPa, reference velocity was a constant 1400 K.
Briehl, D.↗
Three-Dimensional Nacelle Aeroacoustics Code With Application to Impedance Education
A three-dimensional nacelle acoustics code that accounts for uniform mean flow and variable surface impedance liners is developed. The code is linked to a commercial version of the NASA-developed General Purpose Solver (for solution of linear systems of equations) in order to obtain the capability to study high frequency waves that may require millions of grid points for resolution. Detailed, single-processor statistics for the performance of the solver in rigid and soft-wall ducts are presented. Over the range of frequencies of current interest in nacelle liner research, noise attenuation levels predicted from the code were in excellent agreement with those predicted from mode theory. The equation solver is memory efficient, requiring only a small fraction of the memory available on modern computers. As an application, the code is combined with an optimization algorithm and used to reduce the impedance spectrum of a ceramic liner. The primary problem with using the code to perform optimization studies at frequencies above I1kHz is the excessive CPU time (a major portion of which is matrix assembly). The research recommends that research be directed toward development of a rapid sparse assembler and exploitation of the multiprocessor capability of the solver to further reduce CPU time.
Watson, Willie R.↗
Reliability Considerations for Composite Overwrapped Pressure Vessels on Spacecraft
Composite Overwrapped Pressure Vessels (COPVs) are used to store gases under high pressure onboard spacecraft. These are used for a variety of purposes such as propelling liquid fuel etc, Kevlar, glass, Carbon and other more recent fibers have all been in use to overwrap the vessels. COPVs usually have a thin metallic liner with the primary purpose of containing the gases and prevent any leakage. The liner is overwrapped with filament wound composite such as Kevlar, Carbon or Glass fiber. Although the liner is required to perform in the leak before break mode making the failure a relatively benign mode, the overwrap can fail catastrophically under sustained load due to stress rupture. It is this failure mode that is of major concern as the stored energy of such vessels is often great enough ta cause loss of crew and vehicle. The present paper addresses some of the reliability concerns associated specifically with Kevlar Composite Overwrapped Pressure Vessels. The primary focus of the paper is on how reliability of COPV's are established for the purpose of deciding in general their flight worthiness and continued use. Analytical models based on existing design data will be presented showing how to achieve the required reliability metric to the end of a specific period of performance. Uncertainties in the design parameters and how they affect reliability and confidence intervals will be addressed as well. Some trade studies showing how reliability changes with time during a program period will be presented.
Murthy, Pappu L. N.↗
Feasibility Study for Cathodic Protection of Waste Tanks at Hanford
The Hanford Nuclear Reservation site contains approximately 211 million liters of radioactive and chemically hazardous waste arising from nuclear weapons production, beginning with World War II, and continuing through the Cold War. The waste is stored in 177 carbon-steel underground storage tanks, of which 149 are single-shell tanks (SSTs) and the remaining are double-shell tanks (DSTs). The mission of an ongoing River Protection Project is to retrieve the waste from the underground storage tanks and then treat and immobilize (i.e., vitrify) it for disposal. Waste from the older SSTs is being progressively retrieved into the newer DSTs for storage pending treatment, immobilization, and disposal. Waste chemistry controls are in place to mitigate general corrosion, pitting corrosion, and stress corrosion cracking (SCC) and minimize corrosion risks to the carbon steel tank liners of DST at the Hanford Site. The chemistry control program focuses on preserving liner integrity while balancing the need for caustic/nitrite additions that have large downstream impacts on vitrification. Some of the DSTs store salt cake or sludge waste layers contain out-of-specification interstitial liquids that contact the primary tank bottom or sidewall. Remediation of such layers through chemical additions is not practical. At the present time, the most significant leak integrity concern at Hanford is for corrosion of the tank bottoms of DSTs where the solids layer is out of specification because of hydroxide ion depletion and consequently, pH values that are less than 12. Cathodic protection (CP) has been proposed as a possible way to protect the liners of such tanks against corrosion. The objective of this project was to investigate the feasibility of applying CP to Hanford DSTs to mitigate internal corrosion of the carbon steel tank primary liners. The scope of the project included (1) a literature review on the application of CP to storage tank systems, in general, and to waste tanks at the Savannah River Site (SRS) and Hanford, (2) a review of the finite element analysis (FEA) model recently developed to evaluate potentials for a DST, and (3) the development of a boundary element analysis (BEA) model for CP for a DST. Tank AN-107, one of the Hanford DSTs, was selected for this work because (1) the bottommost waste layer in the tank is out-of-specification, and (2) electrochemical and resistivity data, based on recent waste sampling and testing, are available for this tank. The overarching conclusion of this study is that, based on the available information, it is feasible to apply CP to mitigate internal corrosion of the primary liners of the Hanford DSTs. However, significant additional information and work are required before a CP system can be designed. Recommendations for next steps in the design of the CP system will be presented.
WIERSMA, BRUCE↗
Assessment of 3D Codes for Predicting Liner Attenuation in Flow Ducts
This paper presents comparisons of seven propagation codes for predicting liner attenuation in ducts with flow. The selected codes span the spectrum of methods available (finite element, parabolic approximation, and pseudo-time domain) and are collectively representative of the state-of-art in the liner industry. These codes are included because they have two-dimensional and three-dimensional versions and can be exported to NASA's Columbia Supercomputer. The basic assumptions, governing differential equations, boundary conditions, and numerical methods underlying each code are briefly reviewed and an assessment is performed based on two predefined metrics. The two metrics used in the assessment are the accuracy of the predicted attenuation and the amount of wall clock time to predict the attenuation. The assessment is performed over a range of frequencies, mean flow rates, and grazing flow liner impedances commonly used in the liner industry. The primary conclusions of the study are (1) predicted attenuations are in good agreement for rigid wall ducts, (2) the majority of codes compare well to each other and to approximate results from mode theory for soft wall ducts, (3) most codes compare well to measured data on a statistical basis, (4) only the finite element codes with cubic Hermite polynomials capture extremely large attenuations, and (5) wall clock time increases by an order of magnitude or more are observed for a three-dimensional code relative to the corresponding two-dimensional version of the same code.
Watson, W. R.↗
Double-Shell Tank Primary Bottom Visual Inspection Results - 20025
A pressing need for the Double-Shell Tank Integrity Program at Hanford is of the ability to inspect the bottom of the tanks. Though the DSTs' annulus spaces (the space between the internal and external tank walls) have been inspected visually since 1992 and with Ultrasonic Testing (UT) since 1996, inspections of the tank bottoms have been able to be conducted due to limitations of available technology, omitting about 40 percent of the tank surface below the maximum fill level from routine inspection. Visual inspections of the tank annulus have been conducted up to five times in some DSTs and portions of the annulus space for all of the DSTs has been inspected twice with UT. This region includes the walls of the primary tank and secondary liner along with accessible portions of the secondary liner bottom. Due to this lack of technology, the degradation of the primary tank bottom in Tank AY-102 was undetected until the tank leaked into its annulus space, confirmed in 2012. Since that time, WRPS has been working with the nondestructive examination community and the Pacific Northwest National Laboratory, to evaluate potential technologies to conduct these challenging remote inspections. Recent work has included the development, testing, and deployment of several remote visual inspection technologies to observe the condition of the primary tank bottom of the DSTs by leveraging air distribution slots in the refractory pad on which it rests. Robotic solutions to conduct this inspection were developed with a detailed understanding of the physical configuration and operational logistics. Understanding and subsequent communication of these details to vendors within the robotics and nondestructive examination community was a critical component to the successful production of these new tools. Throughout the FY16-FY18 years, vendors from nondestructive examination community were solicited for ideas to meet the tank bottom inspection challenge. Two tank bottom visual inspection solutions were then pursued to meet that challenge. Both tools were successfully deployed at Tank AP-107, and provided valuable visuals, never before obtained from the under tank environment of a double-shell tank. While there are minor opportunities for improvement identified with each system, general outcomes were overwhelmingly positive. Both systems were successfully able to navigate the refractory air slot pattern from the outer edge to the tank center and record video footage. The micro-crawler provided high quality and very stable footage through the air slot pattern, but took longer to deploy into the slots and traverse through them than the alternative system. The push-pull tethered camera was able to navigate all seven of its target air slots in a matter of a few hours, which included deployment, movement between slot entrances, and complete removal of the system from the annulus environment. Through these air slots, new information was gained about the tank bottom and refractory pad condition of tank AP-107, AP-106, AP-108, and AN-102. While some debris was noted in the air slots, including sand, chipped refractory, and construction materials, the refractory was found to be structurally stable and adequately supporting the primary tank bottom through the full diameter of the tank. Primary tank bottom steel exterior was found to be in good condition, free of ongoing or aggressive corrosion conditions. Looking toward the future, robotic access to and visual inspection of refractory air slots and the primary tank bottom steel has now proven viable. Incorporating periodic air slot inspections as a regular practice within the Double-Shell Tank Integrity Program is the next step, allowing trending of any changes in condition. As ultrasonic testing infrastructure was leveraged to complete the initial system deployments described in this report, it makes sense to adopt that same strategy for ongoing periodic examinations and deploy these primary tank bottom inspection tools alongside ultrasonic testing operations. Development of visual inspection tools to evaluate the primary tank bottom region of the double-shell tanks was planned as the first stage of inspection. Continued development of volumetric sensors and incorporation of these inspection tools into Hanford's ongoing Double-Shell Tank Integrity Program are the next steps, seeking to continuously expand understanding of asset integrity and remaining useful life. (authors)
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Inspection Tools for Hanford Tanks and Waste Transport Systems - 20444
Recent integrity issues in the double-shell tanks (DST) at Hanford have motivated the need for developing innovative tools that can provide information regarding the health of the tanks. These issues include the primary linear failure of AY-102 and recent concerns of thinning in the DST secondary liners. Other concerns include erosion or corrosion on transfer lines and processing pipes. In recent years, Florida International University (FIU) has supported DOE-EM by developing tools that can assist in understanding the health of tanks and waste transport system at Hanford. More specifically, FIU has developed a miniature rover that can be deployed through small risers and gain access to refractory slots in the Hanford DSTs. It traverses through the slots on the primary liner upside down via magnets to avoid debris in the slots. Recent modifications include a spring loaded magnetic arm that allows the unit to traverse over large weld seams but does not reduce the overall functionality of the system. The system has also incorporated a control capsule that will sit within the annulus of the tank and improves on issues related to signal and voltage loss over long tether lines. Lastly, the unit is also being augmented with a second module that will include a means to prep the tank surface and obtain a thickness measurement using a dual element ultrasonic sensor. FIU has also developed a 6-inch peristaltic pipe crawler that operates similar to the previous pipe crawlers developed at FIU. This crawler is a marsupial type crawler that will navigate through the 6-inch drain lines, and deploy a small rover at the entrance of the drain slots. This rover will also traverse upside down on the secondary liner and provide information regarding the health of the liner. An initial prototype for the crawler unit has been developed, assembled and tested. The system is pneumatic and consists of three modules - two grippers and one extender. The validation tests are conducted in a mockup of the drain lines and demonstrate the system's ability to navigate through long pipe lengths and elbows. In this paper, a general overview of each of the aforementioned systems is presented along with results from testing and demonstrations that shows the applicability of each system. (authors)
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