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Idaho National Laboratory
Recent Equipment Development for Fueling and Testing Radioisotope Power Systems
Kelly L. Lively Department Manager Jaymon C. Birch Mechanical Engineer Shad E. Davis Mechanical Engineer Craig E. Dees Mechanical Engineer Greg A. Hula Transportation Coordinator Kade R. Munns Mechanical Engineer Stephen G. Johnson Division Director
February 25, 2015
Capabilities
• Idaho National Laboratory (INL) is an 860-square
mile, federal reservation located in a remote, desert site of southeast Idaho.
• The INL’s Space Nuclear Power and Isotope Technologies Division established the resources, equipment & facilities required to provide nuclear-fueled, Radioisotope Power Systems (RPS) to Department of Energy (DOE) Customers.
• RPS are designed to convert the heat
generated by decay of iridium clad 238PuO2 fuel pellets into electricity that is used to power missions in remote, harsh environments.
• Utilization of nuclear fuel requires adherence to governing regulations and the INL provides unique capabilities to safely fuel, test, store, transport and integrate RPSs to supply power—supporting mission needs.
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• INL performs work as: nuclear operations (Nuclear Space)
and non-nuclear operations (Laboratory Space) at the INL and Off-site Locations to provide Radioisotope Power Systems to DOE Customers.
Nuclear Facility − Space & Security Power Systems Facility (SSPSF)
Non Nuclear Facilities − Engineering Development Laboratory (EDL) − Radioisotope Systems Training & Storage Facility
(RSTSF) − Radioisotope Thermoelectric Generator
Transportation System (RTGTS) − Technology Development Facility (TDF)
(RSTSF)
(RTGTS)
INL Materials and Fuels Complex
SSPSF
EDL
(SSPSF)
(EDL)
Capabilities
(TDF)
(TDF) 3
• INL—Non-Nuclear Activities
• Module Pre-Assembly • Graphite & Insulation Bakeout • 9516 & 9904 Cask Certifications
• INL—Nuclear Activities – General Purpose Heat Source Assembly – RPS Fueling – RPS Assembling – RPS Acceptance Testing – RPS Storing, Maintenance & Monitoring – RPS Transporting – RPS End User Handling for Mission Testing
and Integration
General Purpose Heat Source (GPHS)
PuO2 Iridium-Clad Fuel Pellet
PuO2 Unclad Fuel Pellet
GPHS before RPS Fueling
Capabilities
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• Capability to fuel an RPS in either the IAAC, Re-Packaging Glovebox and MFG in parallel.
• SSPSF Houses 3 Gloveboxes that support RPS assembly operations and are equipped with environmental control systems
− IAAC & MFG are capable of maintaining an atmosphere of <5 ppm O2, <10 ppm H2O, <15 ppm N2
− The Re-packaging Glovebox is capable of maintaining an atmosphere of <25 ppm O2, <50 ppm H2O
− Planetary Protection Capability (Vaporous Hydrogen Peroxide)
Multi-Purpose Fueling Glovebox (MFG)
RPS Assembly Welding Planetary Protection
Re-Packaging Glovebox
RPS Assembly Fuel Clad Re-Packaging Welding
Inert Atmosphere & Assy Chamber (IAAC)
RPS Assembly Welding
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New Capabilities
VHP Cabinet configuration on the Multipurpose Fueling Glovebox for sterilization cycle development and validation
Vaporous Hydrogen Peroxide (VHP) for Planetary Protection: • Implementation of planetary protection methods are dictated by NASA requirements • Only dry heat sterilization is approved by NASA • Proposed VHP sterilization method alternative to dry heat due to temperature constraints of certain ASRG components • Planned use of VHP: Glovebox Interior Surfaces, Generator Exterior, Large and Heat-Sensitive Tooling • Planned use of Dry Heat: Insulation, Non Heat Sensitive Generator Metal/Non-Metal Components
FY15 Planned Goals: • Complete VHP operation procedure validation and
complete final approval and release. • Initiate operator training and qualification process • Re-validate cycles developed for the MFG main enclosure
and Antechamber 2 • Develop improved cycle for Antechamber 1 to assure
sterility on all reproducibility runs
FY14 Accomplishments: • Successfully developed sterilization cycles for main chamber and one of
two passboxes of MFG (further process development needed for 2nd passbox)
• Used chemical indicators for developing parameters (i.e. injection rate and concentration) for individual cycles of the three enclosures
• Used biological indicators (disks) inoculated with 106 spores of the hardiest VHP-resistant microbes (Geobacillus Stearothermophilus) as the qualitative verification that a industry-accepted microbe reduction was obtained
• Used real-time H2O2 vapor sensor to measure concentration within the chambers
Multipurpose Fueling Glovebox
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New Capabilities
New Capabilities
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High Temperature Graphite Furnace Installation (9/30/15) • Graphite Furnace Used to Bake Off Impurities from Graphite Materials Used for GPHS
Module Assembly • Replacing existing Molybdenum Furnace with Graphite Furnace • Increasing Capability and Providing Redundancy for Single-Point Failure • Integrating new Graphite Furnace to Existing Glovebox • Upgrading Environmental Control System with Foraged System • Expected Graphite Furnace Delivery to INL April 2015 • Installation planned to begin May 2015 • DOE Level 2 Milestone
Existing Graphite Furnace Glovebox Integration of the GFE Glovebox with New Furnace System at Vendor’s Facility
• Thermal Vacuum Testing. SSPSF houses two
thermal vacuum chambers that simulate near-earth space vacuum; electrical output is measured.
− Cylindrical Test Chambers: 6ft. Diameter, 9 ft. Long
− High Vacuum Range: 10-6 Torr − One Chamber equipped with a cryogenic
shroud simulating the coldness of space: -185 to 120°C
− Avoidance of Overheating of Natural Earth Magnets in Alternator –increased vacuum pump-down speeds with turbo pumps instead of legacy diffusion pumps
New Capabilities
Thermal Vacuum Testing Chamber (Rm 112)
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• Updating Human Machine Interface (HMI) with dual touch screen control • Updating to a Programmable Logic Controller (PLC) with integrated touch screen • Installing numerically controlled process valves for chamber pump down, chamber backfill and RPS
backfill • DOE Level 2 Milestone • Installation planned to begin July 2015
Chamber Backfill Valve
Chamber Pump Down Valve
New HMI Cabinet
PLC Touch Screen
PLC Cabinet Existing HMI Cabinet
Thermal Vacuum Testing Chamber (Rm 111)
New Capabilities
• Multi-Disciplined Work Force of Degreed Engineers (Mechanical, Electrical, Materials, Instrumentation & Control)
− Systems Engineering
− Applied Engineering
− Tool Design
− Process Development (Training & Execution)
• RPS Program governed by Quality Assurance Program Plan
– Certified Quality Engineers
– Quality Assurance Inspectors
• Nuclear Operators & Technicians
– Perform Hands-on Nuclear & Non-Nuclear Work Scope
– Electrical, Mechanical, Welding
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Human Capital
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The National Nuclear Laboratory
Nuclear Operations Performed in SSPSF • 2-Story, 10,000 Square Foot Building
• DOE Hazard Category 2 (HC-2) Non Reactor Nuclear Facility
− Based on Estimated Inventory of Radioactive Materials
• DOE Performance Category 3 (PC-3)
− Seismic Design Included Analysis of Structural Capability for Non-Seismic and Seismic Loads
Space and Security Power Systems Facility (SSPSF)
1st Floor: Process Equipment
− Gloveboxes
− Fume Hoods
− Testing Equipment
− High-Bay for Receipt and Handling of Department of Transportation (DOT) Shipping Packages
− Overhead Cranes
Systems Shared with Other Facilities or Supplied Externally to SSPSF
− Argon
− Instrument Air
− Normal & Standby Electrical Power
2nd Partial Floor: Building System Equipment
− Heating and Ventilation
− Process Chilled Water System
− Glovebox-Related Vacuum Pumps
Capabilities
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• SSPSF Houses Testing Equipment . An RPS is subjected to a series of acceptance tests, once fueled.
• Vibration Testing simulates the physical environment the RPS will encounter on the launch pad.
• RPS is mounted vertically to either an exciter table or slip table and tested at various frequencies. −Max force 30,000 lbf −Frequency range ~10 Hz to 2,000 Hz −Maximum acceleration 100 g −Maximum velocity 70 in. per second −Maximum displacement 1 in. −Maximum static load (vertical) 3,000 lb −Maximum load 100g vector 80 lb
Vibration Testing
Capabilities
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• Mass Properties Testing is performed to determine
characteristics of the RPS that are important to the flight stability of the spacecraft.
• These measurements very accurately determine the weight of the RPS, its center of gravity (CG), and its moments of inertia (MOI). Equipment capabilities include:
− CG to sphere of 10mm − MOI +/- 0.1%
• Magnetics Testing is a three-dimensional map of the magnetic-field strength obtained by an array of extremely sensitive magnetometers suspended in the test station at fixed positions.
• The RPS is rotated on a turntable to expose all sides to the magnetometers. Equipment capabilities include:
− 4 Tri-axial Digital Fluxgate Magnetometers − Non-Magnetic Rotation Platform − Field Measurement Range: ±65,000nT − Sensitivity 28 Bit at 4096 sample averaging
Mass Properties Testing
Capabilities
Magnetics Testing 14
• RPSs and fueled clads delivered to or shipped from
SSPSF are transported in accordance with DOT regulations in appropriate shipping packages.
• INL responsible for custodianship of DOT Type-B Shipping Packages/Casks
• Fueled RPSs are placed in 9904 Shipping Casks and transported using specialized transportation trailers.
− Radioisotope Thermoelectric Generator Transportation System (RTGTS)
− DOT Certified − Data Acquisition System for Payload − Active Cooling System
• INL responsible for maintenance of the Safety Analysis Report-Packaging (SARP) for casks.
− Fueled Clads: 9516 Casks − Fueled RPS: 9904 Cask
Capabilities
9904 Shipping Cask
9516 Shipping Cask
Radioisotope Thermoelectric Generator Transportation System (RTGTS)
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Non-Nuclear Operations Performed in EDL • 2-Story, 4,000 Square Foot Building
1st Floor: Process Equipment
− High Temperature Vacuum Furnace
− Electron Beam Welder
− Forming Presses
− Sheet Metal Tester
− Laser Etcher
2nd Partial Floor (Mezzanine): Process Equipment
− Graphite Vacuum Furnace (Glovebox Access)
− Two Welding Gloveboxes
Capabilities Engineering Development
Laboratory (EDL)
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• Graphite Vacuum Furnace. This furnace is utilized to off-
gas impurities from the GPHS graphite components. The components are then stored in canisters with an argon cover gas to keep them from oxidizing which would reduce the quality of the thermal conductivity.
− 1700° C maximum − Vacuum: 1 x 10-5 Torr. No partial vacuum control − Glove Box atmosphere control: < 5 PPM H2O, < 10 PPM O2 − Graphite elements and liners − 12”H x12”W x 24”D work chamber − Turbo pump
Capabilities
Graphite Vacuum Furance
General Purpose Heat Source (GPHS)
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• Two welding gloveboxes are used in the fabrication process of
stainless steel hardware components used as containment vessels for shipping radioactive fuel. The capabilities include:
• Welding Glove Box #1
−AMET Automated Welding System (GTAW)
−5 axis controlled motion: Rotation, X, Y, Z, AVC (Automatic Voltage Control: manually positioned)
−Wire feed, magnetic arc oscillator, video camera system
−Miller XMT 304 CC/CV power supply 300 Amp
−Glove Box atmosphere controlled: , <10 ppm O2, < 5 ppm H2O, < 10 ppm Ni
• Welding Box Box #2
−AMET Automated Welding System (GTAW)
−3 axis controlled motion: Rotation, X and Z (AVC)
−Fixture, 4 bar lathe with 16” length, 6” swing capabilities
−Wire feed, magnetic arc oscillator, video camera system
−Miller XMT 304 CC power supply 300Amp
−Glove Box atmosphere controlled: , <10 ppm O2, < 5 ppm H2O, < 10 ppm Ni
Capabilities
Welding Glove Box #1
Welding Glove Box #2
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• EDL houses other equipment that is utilized for fabrication, heat
treating and marking RPS Components:
• High Temperature Vacuum Furnace
• 1500° C maximum
• Vacuum: 1 x 10-5 Torr with manual partial vacuum (inert gas) control
• No atmosphere control
• Molybdenum elements and liner
• 12” x 12” x 30” (HWD) work chamber
• 220 lb. load limit
• Diffusion pump
• Electron Beam Welder
• 150 KV, 100 Ma
• Internal fixture (Rotation, X-Y)
• 24” x 36” x 52” maximum work space (depending on fixture configuration)
Capabilities
High Temperature Vacuum Furnace
Electron Beam Welder
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• EDL houses other equipment that is utilized for fabrication, heat
treating and marking RPS Components:
• Air Oven
• 40 - 200° C
• 12” x 16” x 18” (HWD) work chamber
• 50 lb. load limit
• No atmosphere control
• Stainless Steel chamber
• Manual control
• Laser Etcher
• Alignment laser, class 2M
• Etching laser, embedded class 4
• 10 W etching laser
• 24” x 16” x 6” (X,Y,Z) work chamber
Capabilities
Air Oven
Laser Etcher
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Nuclear Operations Performed in SSPSF • 2-Story, 10,000 Square Foot Building
• DOE Hazard Category 2 (HC-2) Non Reactor Nuclear Facility
− Based on Estimated Inventory of Radioactive Materials
• DOE Performance Category 3 (PC-3)
− Seismic Design Included Analysis of Structural Capability for Non-Seismic and Seismic Loads
Space and Security Power Systems Facility (SSPSF)
1st Floor: Process Equipment
− Gloveboxes
− Fume Hoods
− Testing Equipment
− High-Bay for Receipt and Handling of Department of Transportation (DOT) Shipping Packages
− Overhead Cranes
Systems Shared with Other Facilities or Supplied Externally to SSPSF
− Argon
− Instrument Air
− Normal & Standby Electrical Power
2nd Partial Floor: Building System Equipment
− Heating and Ventilation
− Process Chilled Water System
− Glovebox-Related Vacuum Pumps
Capabilities
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