Publications

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In preparation for developing a Z-pinch IFE power plant, the interaction of ferritic steel with the coolant, FLiBe, must be explored. Sandia National Laboratories Fusion Technology Department was asked to drop molten ferritic steel and FLiBe in a vacuum system and determine the gas byproducts and ability to recycle the steel. We tried various methods of resistive heating of ferritic steel using available power supplies and easily obtained heaters. Although we could melt the steel, we could not cause a drop to fall. This report describes the various experiments that were performed and includes some suggestions and materials needed to be successful. Although the steel was easily melted, it was not possible to drip the molten steel into a FLiBe pool Levitation melting of the drop is likely to be more successful.

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This paper describes the liquid metal integrated test system (LIMITS) at Sandia National Laboratories. This system was designed to study the flow of molten metals and salts in a vacuum as a preliminary study for flowing liquid surfaces inside of magnetic fusion reactors. The system consists of a heated furnace with attached centrifugal pump, a vacuum chamber, and a transfer chamber for storage and addition of fresh material. Diagnostics include an electromagnetic flow meter, a high temperature pressure transducer, and an electronic level meter. Many ports in the vacuum chamber allow testing the thermal behavior of the flowing liquids heated with an electron beam or study of the effect of a magnetic field on motion of the liquid. Some preliminary tests have been performed to determine the effect of a static magnetic field on stream flow from a nozzle.

Smoke can cause interruptions and upsets in active electronics. Because nuclear power plants are replacing analog with digital instrumentation and control systems, qualification guidelines for new systems are being reviewed for severe environments such as smoke and electromagnetic interference. Active digital systems, individual components, and active circuits have been exposed to smoke in a program sponsored by the U.S. Nuclear Regulatory Commission. The circuits and systems were all monitored during the smoke exposure, indicating any immediate effects of the smoke. The major effect of smoke has been to increase leakage currents (through circuit bridging across contacts and leads) and to cause momentary upsets and failures in digital systems. This report summarizes two previous reports and presents new results from conformal coating, memory chip, and hard drive tests. The report describes practices for mitigation of smoke damage through digital system design, fire barriers, ventilation, fire suppressants, and post fire procedures.

Smoke is known to cause electrical equipment failure, but the likelihood of immediate failure during a fire is unknown. Traditional failure assessment techniques measure the density of ionic contaminants deposited on surfaces to determine the need for cleaning or replacement of electronic equipment exposed to smoke. Such techniques focus on long-term effects, such as corrosion, but do not address the immediate effects of the fire. This document reports the results of tests on the immediate effects of smoke on electronic equipment. Various circuits and components were exposed to smoke from different fields in a static smoke exposure chamber and were monitored throughout the exposure. Electrically, the loss of insulation resistance was the most important change caused by smoke. For direct current circuits, soot collected on high-voltage surfaces sometimes formed semi-conductive soot bridges that shorted the circuit. For high voltage alternating current circuits, the smoke also tended to increase the likelihood of arcing, but did not accumulate on the surfaces. Static random access memory chips failed for high levels of smoke, but hard disk drives did not. High humidity increased the conductive properties of the smoke. The conductivity does not increase linearly with smoke density as first proposed; however, it does increase with quantity. The data can be used to give a rough estimate of the amount of smoke that will cause failures in CMOS memory chips, dc and ac circuits. Comparisons of this data to other fire tests can be made through the optical and mass density measurements of the smoke.

Smoke can cause electronic equipment to fail through increased leakage currents and shorts. Sandia National Laboratories is studying the increased leakage currents caused by smoke with varying characteristics. The objective is to develop models to predict the failure of electronic equipment exposed to smoke. This requires the collection of data on the conductivity of smoke and knowledge of critical electrical systems that control high-consequence operations. We have found that conductivity is a function of the type of fuel, how it is burned, and smoke density. Video recordings of highly biased dc circuits exposed in a test chamber show that during a fire, smoke is attracted to high voltages and can build fragile carbon bridges that conduct leakage currents. The movement of air breaks the bridges, so the conductivity decreases after the fire is extinguished and the test chamber is vented. During the fire, however, electronic equipment may not operate correctly, leading to problems for critical operations dependent on electronic control. The potential for electronic failure is highly dependent on the type of electrical circuit, and Sandia National Laboratories plans to include electrical circuit modeling in the failure models.

Smoke from plastics can cause immediate problems in electrical equipment in the form of shorting and increased leakage currents, as well as long-term corrosion (metal loss). The short-term problems can be especially serious for critical control instrumentation such as that found in nuclear reactors or telecommunications systems. The US Nuclear Regulatory Commission and Sandia National Laboratories are sponsoring a program to determine the modes and probabilities of digital equipment failure during exposure to smoke and up to 24 hours after the exposure. Early tests on computer systems have shown that the most common immediate problems are temporary and are likely to be caused by increased leakage currents. High-voltage circuits are especially vulnerable since the charged particles in smoke are drawn to those surfaces. To study failure probabilities, smoke exposure tests with real-time measurements will be carried out to determine how the electrical properties of the environment are affected by smoke concentration and content. Digital communication cable will be included in the tests because temporary shorts that cannot be detected through dc measurements may cause interruptions in communications between computers. The reaction of the equipment to changed electrical properties of the environment will be modeled. Equipment that can be used for testing and modeling is being solicited.

Nuclear power plants are converting to digital instrumentation and control systems; however, the effects of abnormal environments such as fire and smoke on such systems are not known. There are no standard tests for smoke, but previous smoke exposure tests at Sandia National Laboratories have shown that digital communications can be temporarily interrupted during a smoke exposure. Another concern is the long-term corrosion of metals exposed to the acidic gases produced by a cable fire. This report documents measurements of basic functional circuits during and up to 1 day after exposure to smoke created by burning cable insulation. Printed wiring boards were exposed to the smoke in an enclosed chamber for 1 hour. For high-resistance circuits, the smoke lowered the resistance of the surface of the board and caused the circuits to short during the exposure. These circuits recovered after the smoke was vented. For low-resistance circuits, the smoke caused their resistance to increase slightly. A polyurethane conformal coating substantially reduced the effects of smoke. A high-speed digital circuit was unaffected. A second experiment on different logic chip technologies showed that the critical shunt resistance that would cause failure was dependent on the chip technology and that the components used in the smoke exposures were some of the most smoke tolerant. The smoke densities in these tests were high enough to cause changes in high impedance (resistance) circuits during exposure, but did not affect most of the other circuits. Conformal coatings and the characteristics of chip technologies should be considered when designing circuitry for nuclear power plant safety systems, which must be highly reliable under a variety of operating and accident conditions. 10 refs., 34 figs., 18 tabs.

Advanced reactor systems are likely to use protection systems with digital electronics that ideally should be resistant to environmental hazards, including smoke from possible cable fires. Previous smoke tests have shown that digital safety systems can fail even at relatively low levels of smoke density and that short-term failures are likely to be caused by circuit bridging. Experiments were performed to examine these failures, with a focus on component packaging and protection schemes. Circuit bridging, which causes increased leakage currents and arcs, was gauged by measuring leakage currents among the leads of component packages. The resistance among circuit leads typically varies over a wide range, depending on the nature of the circuitry between the pins, bias conditions, circuit board material, etc. Resistance between leads can be as low as 20 k{Omega} and still be good, depending on the component. For these tests, the authors chose a printed circuit board and components that normally have an interlead resistance above 10{sup 12} {Omega}, but if the circuit is exposed to smoke, circuit bridging causes the resistance to fall below 10{sup 3} {Omega}. Plated-through-hole (PTH) and surface-mounted (SMT) packages were exposed to a series of different smoke environments using a mixture of environmentally qualified cables for fuel. Conformal coatings and enclosures were tested as circuit protection methods. High fuel levels, high humidity, and high flaming burns were the conditions most likely to cause circuit bridging. The inexpensive conformal coating that was tested - an acrylic spray - reduced leakage currents, but enclosure in a chassis with a fan did not. PTH packages were more resistant to smoke-induced circuit bridging than SMT packages. Active components failed most often in tests where the leakage currents were high, but failure did not always accompany high leakage currents.

Smoke can adversely affect digital electronics; in the short term, it can lead to circuit bridging and in the long term to corrosion of metal parts. This report is a summary of the work to date and component-level tests by Sandia National Laboratories for the Nuclear Regulatory Commission to determine the impact of smoke on digital instrumentation and control equipment. The component tests focused on short-term effects such as circuit bridging in typical components and the factors that can influence how much the smoke will affect them. These factors include the component technology and packaging, physical board protection, and environmental conditions such as the amount of smoke, temperature of burn, and humidity level. The likelihood of circuit bridging was tested by measuring leakage currents and converting those currents to resistance in ohms. Hermetically sealed ceramic packages were more resistant to smoke than plastic packages. Coating the boards with an acrylic spray provided some protection against circuit bridging. The smoke generation factors that affect the resistance the most are humidity, fuel level, and burn temperature. The use of CO{sub 2} as a fire suppressant, the presence of galvanic metal, and the presence of PVC did not significantly affect the outcome of these results.

Last year the USNRC initiated a program at Sandia National Laboratories to determine the potential impact of smoke on advanced safety-related digitial instrumentation. In recognition of the fact that the reliability of safety-related equipment during or shortly after a fire in a nuclear power plant is more risk significant than long-term effects, we are concentrating on short-term failures. We exposed a multiplexer module board to three different types of smoke to determine whether the smoke would affect its operation. The operation of the multiplexer board was halted by one out of the three smoke exposures. In coordination with Oak Ridge National Laboratory, an experimental digital safety system was also smoke tested. The series of tests showed that smoke can cause potentially serious failures of a safety system. Most of these failures were intermittent and showed that smoke can temporarily interrupt communication between digital systems.

This study assessed the impact of aging on the performance and reliability of active fire protection systems including both fixed fire suppression and fixed fire detection systems. The experience base shows that most nuclear power plants have an aggressive maintenance and testing program and are finding degraded fire protection system components before a failure occurs. Also, from the data reviewed it is clear that the risk impact of fire protection system aging is low. However, it is assumed that a more aggressive maintenance and testing program involving preventive diagnostics may reduce the risk impact even further.