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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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