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NTREES Testing and Operations Status

Abstract.

Nuclear Thermal Rockets or NTR's have been suggested as a propulsion system option for vehicles traveling to themoon or Mars. These engines are capable of providing high thrust at specific impulses at least twice that of today'sbest chemical engines. The performance constraints on these engines are mainly the result of temperature limitationson the fuel coupled with a limited ability to withstand chemical attack by the hot hydrogen propellant. To operate atmaximum efficiency, fuel forms are desired which can withstand the extremely hot, hostile environmentcharacteristic of NTR operation for at least several hours. The simulation of such an environment would require anexperimental device which could simultaneously approximate the power, flow, and temperature conditions which anuclear fuel element (or partial element) would encounter during NTR operation. Such a simulation would allowdetailed studies of the fuel behavior and hydrogen flow characteristics under reactor like conditions to be performed.Currently, the construction of such a simulator has been completed at the Marshall Space Flight Center, and will beused in the fiiture to evaluate a wide variety of fuel element designs and the materials of which they are fabricated.This present work addresses the operational status of the Nuclear Thermal Rocket Element Environmental Simulatoror NTREES and some of the design considerations which were considered prior to and during its construction.

Joint^.._^l/Nuclear Systems Branch

Ir

Propulsion Conference - 2007117-eejedto Excel—Driven to

NTREES Testing and Operations Status

Bill Emrich - NASA Marshall Space Flight Center

Nuclear Thermal Rocket Element Environmental ER'A.

Simulator (NTREES) Overview F-41 '9i,Pe^edto Excel—Driven

to ExPo

V=024/Nuclear Systems Branch

A key technology element in Nuclear Thermal Propulsion is the developmentof fuel materials and components which can withstand extremely hightemperatures while being exposed to flowing hydrogen. NTREES provides acost effective method for rapidly screening of candidate fuel componentswith regard to their viability for use in NTR systems

• The NTREES is designed to mimic the conditions (minus the radiation) towhich nuclear rocket fuel elements and other components would besubjected to during reactor operation.

• The NTREES consists of a water cooled ASME code stamped pressurevessel and its associated instrumentation coupled with inductive heaters tosimulate the heat provided by the fission process.

• The NTREES has been designed to allow hydrogen gas to be injected intointernal flow passages of a test article mounted in the chamber.

Numerous laboratory upgrades in 4205/110 have been required to supportthe operation of NTREES. These modifications include the installation of acooling water system, a power distribution system consisting of switchpanels and transformers, and a propellant gas feed/exhaust system.

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Use of Depleted Uranium (DU) in NTREES F , . , ;,,%,"edro Excel—Driven jO Exp\o

—10=01- ER24/Nuclear Systems Branch

The NTREES system has been reviewed and approved by the MSFC RadiationSafety Officer (RSO) and has been licensed by the NRC to handle Depleted Uranium

• The Operating Procedures have been approved by the RSO• Filters have been installed on all vent lines (0.3 hum) to capture DU particles

which escape the test element• A mass spectrometer on the vent line monitors the exhaust for traces of U238 (DU)

MSFC License Application

NRC License allowing MSFCMSFC License Application Authorizing use of Depleted

To Possess Up to 27.3 kg

For use or Depleted uranium Uranium in 4205/110

of Depleted Uranium

Nuclear Thermal Rocket Element Environmental ' 'Simulator (NTREES) Overview

Excel-

o^9in-'ejed to.DM-I' to e

rERNINuclear Systems Branch

General Description:

• Water cooled ASME coded test vessel rated for 1050 psi• GN2 (facility) and GH 2 (trailer) gas supply systems• Vent system (combined GN 2/GH 2 flow)• 50kW RF power supply with induction coil• Water cooling system (test chamber, exhaust mixer and RF

system)• Control & Data Acquisition implemented via LabView program• Extensive H 2 leak detection system• Data acquisition system consists of a pyrometer suite for axial

temperature measurements and a mass spectrometer• "Fail Safe" design

NTREES Layout — Laboratory Hardware

Test Chamber and RF System eF^9i^Pe^edro Excel—Dri ven t0 Exp\01P

ER24/Nuclear Systems Branch

Key components on test chamber setup:• 50 kW RF power supply (NTREES is sized to accommodate up to 4 MW of RF power)• Exhaust mixer system and heat exchanger to cool and dilute hot hydrogen flow• Backpressure control instrumentation, valves, and filters• Mass spectrometer on vent gas system• Pyrometers to measure test specimen surface temperatures

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NTREES.-- Exhaust Vent Facility

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NTREES Layout - Mechanical Layout - ER 4

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Includes Nitrogen, Hydrogen, and Vent systems• All components and layout are ASME certified• Main chamber is ASME code stamped

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Test Chamber

Exhaust Mixer/Pit HX/Filter Vent line

Bldg 4205, Room 110

— I IGN2 ConGH2 Control Panel

Manifold

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NTREES LayoutLaboratory Hardware Components

9igeeledro Excel—Driven to E%P

ER24/Nuclear Systems Branch

Primary hardware items placed on laboratory floor:• Hazardous Classification of areas around GH 2 panels and external vent• Hydrogen supply from trailer (external); only hooked up during tests• H2 detectors strategically located •

Fenced Area Behind Lab 109

DAQ & Valve Class I, Div II GH2 Isolation

Control RF Power GN2 Control Cooling area 15' radius ValveCabinet Supply Manifold Cabinet water

I I / interface

CTRLComputer

Room 110B GH2 Exhaust Stack onroof, Div I area

surrounded by Div II

All electrical components areexplosion proof in these zones

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Cooling Reliefs

water 0panel

Assembly

NTREES Induction Coil Mounted inChamber with H2 /N2 Mixer Assembly edtoExcel-Drive°tOExp`0^

ER24/Nuclear Systems Branch

NTREES Data Acquisition and Control ER9ino Excel—Driven isp\o^e^edto

—000010- ER24/Nuclear Systems Branch

Provides the following• System monitoring with 7 RTD's, 8 pressure transducers, & 3 flowmeters• Active system to monitor and control test operations• Automatically shuts down the system when anomalous conditions or redline cuts

are detected (e.g. pressure too high or too low, over temperature, high H2concentration, low N 2 flow, etc.)

Serial

Room 110------------------------------- ------ --------------------------------

Eroll Control Room

I 110B

NTREES Electrical/Power System Layout9i°eared to Excel-Drivee to Exp o^

ER24/Nuclear Systems Branch

A number of power system panels are located in room 110• Some power system panels feed the NTREES system (e.g. water, DAQ, etc.)• All other panels will be locked out during testing (e.g. lights, crane, etc.)

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Main Switch Panels

Transformers

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NTREES Power Reserve in PRDL Eo^9ipeeredto

ExcehDriven to E%P

ER24/Nuclear Systems Branch

Lab has capability of providing up to 5 MW of power for induction heating• Two 2.5MW Transformers• High power switch gear• High power conduit going to opposite side of room

m

Transformers

NTREES Operation —Safety Controlsell!! ' " ' ^0

edPe' ro Excel-Driven to EXQ

—..^4/Nuclear Systems Branch

Fail-Safe ComponentsRelief valves on pressurized equipment

- High pressure gas supply lines with fail-closed valves (loss of power/pneumatics)Back pressure control valves (vent)1. Proportional control for chamber and test article pressure2. Fail open3. Pneumatically controlled, safer for GH 2 environment

Emergency ShutdownActively set to safe condition by real-time controllersReal-time controllers operation includes:1. Termination of RF Power2. Closing of GH 2 supply valve3. Opening of outlet vent valves to relieve chamber and test article pressure

Emergency Shutdown Criteria include:- Any room/chamber GH 2 sensor exceeding limit- Loss of cooling water flow- Any E-Stop button activated (pressed)- Watchdog timeout (both controllers monitor each other)- Chamber pressure or delta pressure (too high or erratic behavior)- Pressure (too low) in chamber sampling stream ( GH 2 sensor location)

^ I 1 I

• Conclusionsw

'3^in^e^edto Excel-Driven to ExP

24/Nuclear Systems Branch

• The NTR Element Environmental Simulator is complete and willallow fuel elements or other components to be tested in a hothydrogen environment with or without internal heat generation andenables:

— High temperature (> 3000 K) operation in flowing hydrogen

— A wide range of instrumentation for monitoring test articlebehavior under extreme conditions

— High pressure operation up to 1050 psi

— Close personnel access during operation resulting from forcedcooling of the chamber

• Due to a lack of funding, the NTREES facility is currently sitting in astandby condition pending future authorization to proceed to testing

Summary^^neeredta Excel-Driven to p`o

^..^ d/Nuclear Systems Branch

The NTR Element EnvironmentalSimulator is operational at MSFC and isavailable to begin testing fuel materials

and other components under prototypicalNTR operating conditions