Publications

This report provides guidance on how to adjust temperature measurements from mineral-insulated, metal-sheathed (MIMS) thermocouples (TCs) mounted on metal plates to correct for slow transient response. This information is needed so that more accurate transient temperature measurements can be made. These more accurate temperature measurements are of benefit for both qualification of hardware and as data sets for model validation. The approach was to use a relatively simple first order adjustment to the MIMS TC reading, as compared to a more accurate metal plate temperature measurement. MIMS TCs are used to improve reliability. Results from four data sets were analyzed to determine the time constraint; an overall average of 5.0 s was obtained.

Mineral-insulated, metal-sheathed, Type-K thermocouples are used to measure the temperature of various items in high-temperature environments, often exceeding 1000degC (1273 K). The thermocouple wires (chromel and alumel) are protected from the harsh environments by an Inconel sheath and magnesium oxide (MgO) insulation. The sheath and insulation are required for reliable measurements. Due to the sheath and MgO insulation, the temperature registered by the thermocouple is not the temperature of the surface of interest. In some cases, the error incurred is large enough to be of concern because these data are used for model validation, and thus the uncertainties of the data need to be well documented. This report documents the error using 0.062" and 0.040" diameter Inconel sheathed, Type-K thermocouples mounted on cylindrical surfaces (inside of a shroud, outside and inside of a mock test unit). After an initial transient, the thermocouple bias errors typically range only about +-1-2% of the reading in K. After all of the uncertainty sources have been included, the total uncertainty to 95% confidence, for shroud or test unit TCs in abnormal thermal environments, is about +-2% of the reading in K, lower than the +-3% typically used for flat shrouds. Recommendations are provided in Section 6 to facilitate interpretation and use of the results. .

The purpose of this report is to describe the methods commonly used to measure heat flux in fire applications at Sandia National Laboratories in both hydrocarbon (JP-8 jet fuel, diesel fuel, etc.) and propellant fires. Because these environments are very severe, many commercially available heat flux gauges do not survive the test, so alternative methods had to be developed. Specially built sensors include 'calorimeters' that use a temperature measurement to infer heat flux by use of a model (heat balance on the sensing surface) or by using an inverse heat conduction method. These specialty-built sensors are made rugged so they will survive the environment, so are not optimally designed for ease of use or accuracy. Other methods include radiometers, co-axial thermocouples, directional flame thermometers (DFTs), Sandia 'heat flux gauges', transpiration radiometers, and transverse Seebeck coefficient heat flux gauges. Typical applications are described and pros and cons of each method are listed.

Abstract not provided.

In the fire safety community, the trend is toward implementing performance-based standards in place of existing prescriptive ones. Prescriptive standards can be difficult to adapt to changing design methods, materials, and application situations of systems that ultimately must perform well in unwanted fire situations. In general, this trend has produced positive results and is embraced by the fire protection community. The question arises as to whether this approach could be used to advantage in cook-off testing. Prescribed fuel fire cook-off tests have been instigated because of historical incidents that led to extensive damage to structures and loss of life. They are designed to evaluate the propensity for a violent response. The prescribed protocol has several advantages: it can be defined in terms of controllable parameters (wind speed, fuel type, pool size, etc.); and it may be conservative for a particular scenario. However, fires are inherently variable and prescribed tests are not necessarily representative of a particular accident scenario. Moreover, prescribed protocols are not necessarily adaptable and may not be conservative. We also consider performance-based testing. This requires more knowledge and thought regarding not only the fire environment, but the behavior of the munitions themselves. Sandia uses a performance based approach in assuring the safe behavior of systems of interest that contain energetic materials. Sandia also conducts prescriptive fire testing for the IAEA, NRC and the DOT. Here we comment on the strengths and weakness of both approaches and suggest a path forward should it be desirable to pursue a performance based cook-off standard.

Abstract not provided.

The objective of this report is to develop uncertainty estimates for three heat flux measurement techniques used for the measurement of incident heat flux in a combined radiative and convective environment. This is related to the measurement of heat flux to objects placed inside hydrocarbon fuel (diesel, JP-8 jet fuel) fires, which is very difficult to make accurately (e.g., less than 10%). Three methods will be discussed: a Schmidt-Boelter heat flux gage; a calorimeter and inverse heat conduction method; and a thin plate and energy balance method. Steady state uncertainties were estimated for two types of fires (i.e., calm wind and high winds) at three times (early in the fire, late in the fire, and at an intermediate time). Results showed a large uncertainty for all three methods. Typical uncertainties for a Schmidt-Boelter gage ranged from {+-}23% for high wind fires to {+-}39% for low wind fires. For the calorimeter/inverse method the uncertainties were {+-}25% to {+-}40%. The thin plate/energy balance method the uncertainties ranged from {+-}21% to {+-}42%. The 23-39% uncertainties for the Schmidt-Boelter gage are much larger than the quoted uncertainty for a radiative only environment (i.e ., {+-}3%). This large difference is due to the convective contribution and because the gage sensitivities to radiative and convective environments are not equal. All these values are larger than desired, which suggests the need for improvements in heat flux measurements in fires.

A series of experiments was performed to better characterize the boundary conditions from an inconel heat source ('shroud') painted with Pyromark black paint. Quantifying uncertainties in this type of experimental setup is crucial to providing information for comparisons with code predictions. The characterization of this boundary condition has applications in many scenarios related to fire simulation experiments performed at Sandia National Laboratories Radiant Heat Facility (RHF). Four phases of experiments were performed. Phase 1 results showed that a nominal 1000 C shroud temperature is repeatable to about 2 C. Repeatability of temperatures at individual points on the shroud show that temperatures do not vary more than 10 C from experiment to experiment. This variation results in a 6% difference in heat flux to a target 4 inches away. IR camera images showed the shroud was not at a uniform temperature, although the control temperature was constant to about {+-}2 C during a test. These images showed that a circular shaped, flat shroud with its edges supported by an insulated plate has a temperature distribution with higher temperatures at the edges and lower temperatures in the center. Differences between the center and edge temperatures were up to 75 C. Phase 3 results showed that thermocouple (TC) bias errors are affected by coupling with the surrounding environment. The magnitude of TC error depends on the environment facing the TC. Phase 4 results were used to estimate correction factors for specific applications (40 and 63-mil diameter, ungrounded junction, mineral insulated, metal-sheathed TCs facing a cold surface). Correction factors of about 3.0-4.5% are recommended for 40 mil diameter TCs and 5.5-7.0% for 63 mil diameter TCs. When mounted on the cold side of the shroud, TCs read lower than the 'true' shroud temperature, and the TC reads high when on the hot side. An alternate method uses the average of a cold side and hot side TC of the same size to estimate the true shroud temperature. Phase 2 results compared IR camera measurements with TC measurements and measured values of Pyromark emissivity. Agreement was within measured uncertainties of the Pyromark paint emissivity and IR camera temperatures.

It would not be possible to confidently qualify weapon systems performance or validate computer codes without knowing the uncertainty of the experimental data used. This report provides uncertainty estimates associated with thermocouple data for temperature measurements from two of Sandia's large-scale thermal facilities. These two facilities (the Radiant Heat Facility (RHF) and the Lurance Canyon Burn Site (LCBS)) routinely gather data from normal and abnormal thermal environment experiments. They are managed by Fire Science & Technology Department 09132. Uncertainty analyses were performed for several thermocouple (TC) data acquisition systems (DASs) used at the RHF and LCBS. These analyses apply to Type K, chromel-alumel thermocouples of various types: fiberglass sheathed TC wire, mineral-insulated, metal-sheathed (MIMS) TC assemblies, and are easily extended to other TC materials (e.g., copper-constantan). Several DASs were analyzed: (1) A Hewlett-Packard (HP) 3852A system, and (2) several National Instrument (NI) systems. The uncertainty analyses were performed on the entire system from the TC to the DAS output file. Uncertainty sources include TC mounting errors, ANSI standard calibration uncertainty for Type K TC wire, potential errors due to temperature gradients inside connectors, extension wire uncertainty, DAS hardware uncertainties including noise, common mode rejection ratio, digital voltmeter accuracy, mV to temperature conversion, analog to digital conversion, and other possible sources. Typical results for 'normal' environments (e.g., maximum of 300-400 K) showed the total uncertainty to be about {+-}1% of the reading in absolute temperature. In high temperature or high heat flux ('abnormal') thermal environments, total uncertainties range up to {+-}2-3% of the reading (maximum of 1300 K). The higher uncertainties in abnormal thermal environments are caused by increased errors due to the effects of imperfect TC attachment to the test item. 'Best practices' are provided in Section 9 to help the user to obtain the best measurements possible.

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This paper provides information on three (3) topics related to temperature measurements in an annealing procedure: (1) results of a series of experiments performed by CNIITMASH of the Russian consortium MOHT on their reactor pressure vessel (RPV) temperature measurement probe, (2) a discussion regarding uncertainties and errors in RPV temperature measurements, and (3) predictions from a thermal model of a spherical RPV temperature measurement probe. MOHT teamed with MPR Associates and was to perform the Annealing Demonstration Project (ADP) on behalf of the US Department of Energy, ESEERCo, EPRI, CRIEPI, Framatome, and Consumers Power Co. at the Midland plant. Experimental results show that the CNIITMASH probe errors are a maximum of about 27 C (49 F) during a 15 C/hr (27 F/hr) heat-up but only about 3 C (5.4 F) (0.6%) during the hold portion at 470 C (878 F). These errors are much smaller than those obtained from a similar series of experiments performed by Sandia National Laboratories (Sandia). The discussion about uncertainties and errors shows that results presented as a temperature difference provides a measure of the probe error. Qualitative agreement is shown between the model predictions, the experimental results of the CNIITMASH probe and the experimental results of a series of similar experiments performed by Sandia.

The objective of this project was to provide an assessment of several methods by which the temperature of a commercial nuclear power plant reactor pressure vessel (RPV) could be measured during an annealing process. This project was a coordinated effort between DOE`s Office of Nuclear Energy, Science and Technology; DOE`s Light Water Reactor Technology Center at Sandia National Laboratories; and the Electric Power Research Institute`s Non- Destructive Evaluation Center. Ball- thermocouple probes similar to those described in NUREG/CR-5760, spring-loaded, metal- sheathed thermocouple probes, and 1778 air- suspended thermocouples were investigated in experiments that heated a section of an RPV wall to simulate a thermal annealing treatment. A parametric study of ball material, emissivity, thermal conductivity, and thermocouple function locations was conducted. Also investigated was a sheathed thermocouple failure mode known as shunting (electrical breakdown of insulation separating the thermocouple wires). Large errors were found between the temperature as measured by the probes and the true RPV wall temperature during heat-up and cool-down. At the annealing soak temperature, in this case 454{degrees}C [850`F], all sensors measured the same temperature within about {plus_minus}5% (23.6{degrees}C [42.5{degrees}F]). Because of these errors, actual RPV wall heating and cooling rates differed from those prescribed (by up to 29%). Shunting does not appear to be a problem under these conditions. The large temperature measurement errors led to the development of a thermal model that predicts the RPV wall temperature from the temperature of a ball- probe. Comparisons between the model and the experimental data for ball-probes indicate that the model could be a useful tool in predicting the actual RPV temperature based on the indicated ball- probe temperature. The model does not predict the temperature as well for the spring-loaded and air suspended probes.

This report documents the results of a study regarding the conservatisms in ASME Code Section 3, Class 1 component fatigue evaluations and the effects of Light Water Reactor (LWR) water environments on fatigue margins. After review of numerous Class 1 stress reports, it is apparent that there is a substantial amount of conservatism present in many existing component fatigue evaluations. With little effort, existing evaluations could be modified to reduce the overall predicted fatigue usage. Areas of conservatism include design transients considerably more severe than those experienced during service, conservative grouping of transients, conservatisms that have been removed in later editions of Section 3, bounding heat transfer and stress analysis, and use of the ``elastic-plastic penalty factor`` (K{sub 3}). Environmental effects were evaluated for two typical components that experience severe transient thermal cycling during service, based on both design transients and actual plant data. For all reasonable values of actual operating parameters, environmental effects reduced predicted margins, but fatigue usage was still bounded by the ASME Section 3 fatigue design curves. It was concluded that the potential increase in predicted fatigue usage due to environmental effects should be more than offset by decreases in predicted fatigue usage if re-analysis were conducted to reduce the conservatisms that are present in existing component fatigue evaluations.

Sandia National Laboratories has utilized pool fires for over thirty years to subject military components, weapon mockups and hazardous material shipping containers to postulated transportation accident environments. Most of the tests have been performed in either open pools or wind shielded facilities with little control of visible smoke emissions. Because of the increased sensitivity of environmental issues and because wind generates the biggest uncontrollable effect on the thermal environment in open pool fires, enclosed test facilities with reduced visible emissions have been developed. The facilities are basically water cooled enclosures fitted with controlled air supply systems and high temperature afterburners. The purpose of this paper is to present our experience with both open and enclosed fires. In the first section, a review of the fire test facilities is given. A following section presents a mathematical model behind our approach to characterizing the fire environment. In the last section, data from open and closed fires are compared.

This paper explores the relative contributions of radiative and convective heat transfer to objects in large pool fires. The partitioning process depends on many factors. Results include measurements of the temperature of the objects in the fire, the flames surrounding the object, the total heat flux to the objects and the radiative component of the heat transfer at a few locations using transpiration radiometers. These measurements will be compared with calculations. Agreement between the measured radiative heat flux and the calculated radiative heat flux is good. The convective contribution was calculated from the total and radiative parts and was found to be from 10--20% of the total. 18 refs., 18 figs.