Nonnuclear Subscale Rocket Exhaust Capture System Testing Project

Nonnuclear Subscale Rocket Exhaust Capture System Testing Project Formulation Overview June 28, 2017 Richard T. Rauch, Project Manager NASA Stennis Space Center

Nonnuclear Subscale Rocket Exhaust Capture System (RECS) Testing Project Formulation Overview BRIEFING OUTLINE • Overview of the RECS Concept • Nonnuclear Subscale RECS Conceptual Design • Design Overview • Key Design Issues and Considerations • Project Management Plan Development • • Key Project Elements Project Organization Project Team Key Project Documents 2

Nonnuclear Subscale Rocket Exhaust Capture System Testing Test Facility Conceptual Design How it works: • Hot hydrogen exhaust from an NTP engine flows through a water cooled diffuser that transitions the flow from supersonic to subsonic to enable stable burning with injected O 2. Stennis Space Center Rocket Exhaust Capture System • Afterburning products include steam and excess O 2. • Reactor anomalies could also release radioactive material (including noble gases like Xenon and Krypton) into the flow stream. • Water spray and heat exchanger dissipate heat from the steam/O 2 gas mixture to lower the exhaust temperature and condense steam. • A water tank farm collects H 20 and any radioactive material that might be present in the flow. • Water tank drainage is filtered post test. • GOX Condenser/Heat Exchanger cools residual gases to LN 2 temperatures and condenses O 2 and other entrained gases. • LOX dewar stores LO 2 and any potentially radioactive elements (e. g. , noble gases) until safe for release. • LOX dewar is drained post test via controlled boil-off. NASA/SSC/EA 00 21 -Feb-21 • Preliminary system sizing and performance analysis (including CFD analysis) have been completed, and no operational performance issues have been identified. • All system operating pressures, temperatures, fluid supply and flow requirements are well within SSC’s existing chemical rocket propulsion test capability and experience. 3

Nonnuclear Subscale Rocket Exhaust Capture System Testing Test Facility Conceptual Design Stennis Space Center - Hydrogen Wave Heater 4

Nonnuclear Subscale Rocket Exhaust Capture System Test Facility Benefits of Subscale Proof of Concept Testing Stennis Space Center Purpose: Demonstrate the feasibility, safety, efficacy, and affordability of the ECS concept • • • Matures the TRL level for the NTP ground test facility concept to TRL ~5 (“system prototype validation”). Validates analytic models and enables development of operating procedures (nominal & off-nominal). Supports full-scale NTP ground test facility design, cost, and schedule definition. Supports Nuclear Regulatory Commission (NRC) licensing process for the full-scale A-3 Test Facility. Leverages prior NASA investments in propulsion test infrastructure at SSC. • Bulk of required test infrastructure currently exists and is operational (e. g. , test crews, commodities, equipment) H 2 Heat Exchanger NTP Subscale Test Facility Conceptual Design (at E 3/C 1) GO 2 Chiller Steam Cond Desiccant enser • Diffuser • O 2 Injection • Spray Chamber • Debris Trap Stea Cond m ense r GO 2 Chiller Filter GO Cond 2 ense r Exha ust W ater S torag e LO 2 Storage Key Subscale Test Program Goals • Demonstrate efficacy of the total containment concept • Verify H 2 afterburning GO 2 Cond • Understand transients ensesystem r (e. g. , startup and shutdown) LO 2 Storage Exha • Assess alternative design ust W ater S toragand technology options e infusion options. • Develop and validate test operations procedures. • Supports nuclear site licensing regulatory process • Builds public confidence in NTP testing safety 5

Nonnuclear Subscale Rocket Exhaust Capture System Test Facility Benefits of Subscale Proof of Concept Testing Stennis Space Center • Subscale testing has proven to be a key, cost-effective element in the development of complex systems, including A-3’s rocket diffuser system, which was developed at SSC’s E-3 test Facility: • Evaluation of design alternatives • Operational performance verification and optimization • Subscale testing is critical to the NRC licensing process based on BWXT’s experience with Small Modular Reactor subscale testing. • BWXT’s on-going independent engineering review of the subscale RECS facility design concept recommends that critical A-3 design aspects be represented in the subscale facility design to support NRC licensing requirements. This includes, for example: • NRC-compliant design criteria and standards • NRC-compliant component selection, including scaling requirements, sizing, arrangement, and required redundancies • NRC-compliant Instrumentation and Control (I&C) systems architecture and design, including • Facility control and data integrity assurance and qualification • Calibration, test, and verification processes for safety-related data streams • Future compliance with NRC-required Reactor Protection System (RPS) and Engineered Safety Features Actuation System (ESFAS) requirements • Review of NDAS software and data architectures, requirements, verification testing, and installation for NRC compliance • Initial development of a Phenomena Identification and Ranking Table (PIRT) • BWXT Technical Reports: • Technical Approach Summary Nuclear Thermal Propulsion Ground Test Facility (N ASS-ES 100889), December 2016. • Nuclear Thermal Propulsion Non-Nuclear Subscale Test and Testing Engineering Review (NASS-ES-100890), December 2016. OBSERVATION While the initial subscale cost estimate did not account for the extra costs associated with using subscale testing to support future A-3 NRC site licensing, every effort will be made during the design process to ensure that NRC standards are employed consistent with the available budget. At the very least, design considerations will be undertaken so as not to impede future measures to upgrade the subscale test facility to meet NRC standards and to maximize its ability to support the A 3 site licensing process.

Nonnuclear Subscale Rocket Exhaust Capture System (RECS) Testing Project Formulation Overview BRIEFING OUTLINE • Overview of the RECS Concept • Nonnuclear Subscale RECS Conceptual Design • Design Overview • Key Design Issues and Considerations • Project Management Plan Development • • Key Project Elements Project Organization Project Team Key Project Documents 7

Nonnuclear Subscale Rocket Exhaust Capture System Test Facility Conceptual Design Details 8

Nonnuclear Subscale Rocket Exhaust Capture System Test Facility Conceptual Design Details JTI Report Subscale Facility Design Elements 9

Hot Hydrogen Source Subscale RECS Conceptual Design Details • • • Hot GH 2 Source GH Diffuser LOX Injection Afterburner Water Injection/Spray Chamber Debris Trap • Diffuser • O 2 Injection • Spray Chamber • Debris Trap Steam Conde nser GO 2 Chiller Desiccant Filter GO 2 Conde nser Exhau st Wa ter St orage LO 2 Storage • GH Diffuser, O 2 injection, and Afterburner duct length is proportional to gas temperature, velocity, and gas mixing/reaction lengths. • Latest detailed modeling indicates subscale duct lengths that make vertical afterburning impractical. 10

Hot Hydrogen Source Subscale RECS Conceptual Design Details • • • Hot GH 2 Source GH Diffuser LOX Injection Afterburner Water Injection/Spray Chamber Debris Trap • Diffuser • O 2 Injection • Spray Steam Conde nser GO 2 Chiller Chamber • Debris Trap Desiccant Filter GO 2 Conde nser Exhau st Wa ter St orage LO 2 Storage ROTA TE & STRET CH… • GH Diffuser, O 2 injection, and Afterburner duct length is proportional to gas temperature, velocity, and gas mixing/reaction lengths. • Latest detailed modeling indicates subscale duct lengths that make vertical afterburning impractical. • More detailed modeling of horizontal afterburning is required to support the subscale design. • Subscale testing will confirm model predictions to support A -3 afterburner design. 11

Hot Hydrogen Source Subscale RECS Conceptual Design Details • • • Hot GH 2 Generator GH Diffuser LOX Injection Afterburner Water Injection/Spray Chamber Debris Trap • Diffuser • O 2 Injection • Spray Chamber • Debris Trap Steam Conde nser GO 2 Chiller Desiccant Filter GO 2 Conde nser Exhau st Wa ter St orage LO 2 Storage • GH 2 Heat Sources: • Phase I Natural gas heater ~1600 R • Phase II Hydrogen Wave Heater ~5100 R • Design activities underway: • Scaling, sensitivity, and transient analyses of O 2/GH mixing, afterburning, and water injection • LOX and water injection optimization • Subscale testing will enable optimization of the A-3 design: Diffuser and afterburner design • O 2 injection, O 2/GH mixing, and associated flow rates and spray geometry • Cooling water injection, flow rates, and spray geometry • Characterization and management of facility startup and shutdown transients • Debris tank sizing and optimum water level • Instrumentation requirements 12

H 2 Heat Exchanger Subscale RECS Conceptual Design Details • Steam Condenser • Diffuser • O 2 Injection • Spray Chamber • Debris Trap Steam Conde nser GO 2 Chiller Desiccant Filter GO 2 Conde nser Exhau st Wa ter St orage LO 2 Storage • Design Activity Underway: • Heat Exchanger sizing • Cooling water discharge/retention management • Subscale testing will enable optimization of A-3 Steam Condensers • Validate condenser cooling models • Verify optimum inlet temperatures and pressures • Verify cooling water flow rate requirements • Identify options to minimize/optimize water usage • Water quality impact (industrial water vs. deionized water) • Validate instrumentation requirements 13

H 2 Heat Exchanger Subscale RECS Conceptual Design Details • Engine Exhaust Water Storage • Desiccant Filter • Diffuser • O 2 Injection • Spray Chamber • Debris Trap Steam Conde nser GO 2 Chiller Desiccant Filter GO 2 Conde nser Exhau st Wa ter St orage LO 2 Storage • Design activities underway: • Desiccant filter product survey underway • Minimization of exhaust water storage volume • Subscale testing will enable: • Verification of desiccant filter requirements • Filter technology performance assessment validation 14

H 2 Heat Exchanger Subscale RECS Conceptual Design Details • GOX Condenser • LOX Dewar Storage • Diffuser • O 2 Injection • Spray Chamber • Debris Trap Steam Conde nser GO 2 Chiller Desiccant Filter GO 2 Conde nser Exhau st Wa ter St orage LO 2 Storage • Design activities underway: • GOX Condenser sizing • LOX Dewar sizing and boil-off calculations • LOX Dewar cooling requirements • Subscale testing will enable: • Verification of GOX Condenser performance • Verification of LN 2 flow rate requirements • Optimization of GOX inlet temperatures and flow rates • Definition of pre-start purging and pressure control to prevent GOX condenser freeze up 15

Nonnuclear Subscale Rocket Exhaust Capture System Test Facility Conceptual Design (E-3 Test Facility Plan View) Potential Heat Exchanger Cooling Water Retention Pond ~50 ft 16

Nonnuclear Subscale Rocket Exhaust Capture System Test Facility Conceptual Design (E-3 Test Facility Plan View) Potential Heat Exchanger Cooling Water Retention Pond Accommodating a horizontal afterburning duct… ~50 ft 17

Nonnuclear Subscale Rocket Exhaust Capture System Test Facility Conceptual Design (Detailed Plan View) 8” Industrial Water Supply LOX Dewar 8” Industrial Water Return 1” NPS Exhaust Water Storage O 2 Condenser 4” NPS (Nominal Pipe Size) 1” LN Supply Desiccant Filter Steam Condenser GOX Pre-Chiller & Condenser Spray Chamber & Debris Trap ~6 ft 16” NPS Hot GH 2 Generator 18

Nonnuclear Subscale Rocket Exhaust Capture System Test Facility Conceptual Design (Looking Southwest) Spray Chamber & Debris Trap Desiccant Filter O 2 Condenser Steam Condenser Hot GH 2 Generator LOX Dewar Exhaust Water Storage GOX Pre-Chiller & Condenser 8” Industrial Water Return 8” Industrial Water Supply Northside Drainage Ditch ~12 ft 19

Nonnuclear Subscale Rocket Exhaust Capture System Test Facility Design Options and Recommended Trade Studies • Add a recirculating pump to the spray chamber cooling water loop to massively reduce water storage volume. • This Option also eliminates the need for a steam surface condenser. • Add a steam ejector downstream of the spray chamber to reduce chamber pressure and backpressure at the rocket diffuser exit. (This may be required during full-scale testing depending on test article requirements. ) • Add a vacuum system to remove non-condensable gases (e. g. , ambient air) prior to startup and reduce pressures in the system to saturation pressure (wrt ambient temperature). • Add GN purge and evacuation system upstream of the desiccant dryer to prevent LOX condenser freeze up during startup. Observation: • These options, particularly Options 1 and 2, need to be assessed based on a costbenefit analysis that includes their impact on the NRC licensing process. • Options 3 and 4 appear to be required, in some form or fashion, to be incorporated into the design. 20

Nonnuclear Subscale Rocket Exhaust Capture System Test Facility Transient Operational Modes • Transient operational modes present design challenges • Prestart capture system preparation • Transition from Prestart conditions to Steady Operations • A well defined operating sequence will be required to safely ramp up hot hydrogen flow in coordination with startup of the afterburning and condensing functions of the capture system. (NOTE: Reactor startup differs from the near-instantaneous/full flow start of chemical rocket engines) • Initial GH flow from the hot hydrogen generator could be routed to a flare stack until steady flow is achieved by the hot hydrogen generator • Steady Operations to Shutdown • Coordination of GH and O 2 flows to prevent blowback into the afterburning section and keep any residual O 2 out of the afterburner section. • Removing residual GH trapped between the GH diffuser and the O 2 injection section may require some type of isolation system to keep GH from migrating to the LOX Dewar. • Once isolated, the residual GH could be inerted with GN and routed to a flare stack. • Future subscale reactor simulator test requirements will Involve simulating reactor transients • The RECS will have to detect and react to these variations, in a coordinated and controlled manner, to initiate the reactor shutdown sequence while protecting itself as the simulated reactor proceeds to a safe shutdown and transitions to its cool down phase. • Subscale testing will be critical to developing and demonstrating these capabilities. . Understanding, reacting to, and controlling transient operational modes will be critical to the design validation of the full-scale A-3 RECS, in particular, A-3’s Reactor Protection System (RPS) and Engineered Safety Features Actuation System (ESFAS). 21

Nonnuclear Subscale Rocket Exhaust Capture System Test Facility Summary Schedule and Cost Estimate July 2017 Kickoff? MONTHS • Cost Estimate for Nonnuclear Subscale RECS Test Project : Cost Estimate for Nonnuclear Subscale RECS Test Project • Phase 1 (FY 17 -19), $6. 7 M, Design, Procurement, Construction, and initial Testing – GH 2 operating temperature = 1, 600 R/1, 140 F • Phase 2 (FY 19 -20), $2. 0 M, Hydrogen Wave Heater upgrade and testing – GH 2 temperature increase to 5, 100 R/4, 640 F 22

Nonnuclear Subscale Rocket Exhaust Capture System (RECS) Testing Project Formulation Overview BRIEFING OUTLINE • Overview of the RECS Concept • Nonnuclear Subscale RECS Conceptual Design • Design Overview • Key Design Issues and Considerations • Project Management Plan Development • • Key Project Elements Project Organization Project Team Key Project Documents 23

Nonnuclear Subscale RECS Test Project at E-3 Project Management Elements PROJECT MANAGEMENT ELEMENTS • • • NPR 7120. 5 E, NASA Space Flight Program and Project Management Requirements Project Team Management Approach and Structure Work Breakdown Structure “Suitably Tailored for Ground Test Projects” Financial Management and Control Schedule Management Governance Structure and Associated Reviews Documentation, Configuration Management, and Knowledge Capture Change Tracking and Reporting Decommissioning and Closeout Plan SUMMARY OF KEY PROJECT TECHNICAL ELEMENTS • • • Project Systems Requirement Document Systems Engineering Management Plan (SEMP) Technical Summary Safety and Mission Assurance Plan Summary Risk Management Plan Summary Procurement Plan Summary Construction Management Plan Summary Environmental Management Plan Technology and Commercialization Plan Education and Public Outreach Plan 24

Nonnuclear Subscale RECS Test Project at E-3 Project Management Organization: Design Phase DRAFT NASA Support Liaison Project Manager SSC Project Coordination • EUS Diffuser Development Project • Hydrogen Wave Heater Project Systems Engineer Chief Engineer Business Manager Scheduler Test Conductor Lead Mechanical Project Engineer Lead Electrical Lead Structural Lead Mechanical Lead Electrical S&MA Lead Modeling & Analysis Anticipated Contractor Support SACOM/S 3 • Design Support • Safety and QA Support • Procurement Support • On Demand Construction and Facility Maintenance Support BWXT • Design Services • Procurement Support • Construction Services • NRC Compliance Strategies DRAFT JTI • Design Services • Procurement Support • Construction Services 25

Nonnuclear Subscale RECS Test Project at E-3 Project Management Organization: Procurement and Construction DRAFT NASA Support Liaison Project Manager SSC Project Coordination • EUS Diffuser Development Project • Hydrogen Wave Heater Project Systems Engineer Chief Engineer Business Manager Scheduler Procurement Officer Test Conductor Lead Mechanical Lead Electrical Lead Structural Project Engineer Lead Mechanical Lead Electrical Construction Manager Lead Modeling & Analysis S&MA Lead Quality Assurance Anticipated Contractor Support SACOM/S 3 • Design Support • Safety and QA Support • Procurement Support • On Demand Construction and Facility Maintenance Support BWXT • Design Services • Procurement Support • Construction Services • NRC Compliance Strategies DRAFT JTI • Design Services • Procurement Support • Construction Services 26

Nonnuclear Subscale RECS Test Project at E-3 Project Team • Project Manager – Richard Rauch (NASA/EA 01) • Chief Engineer – David Coote (ETD/EA 01) • Systems Engineer – TBD (NASA/ETD) • Project Engineer – Justin Junell (NASA/ETD) • Lead Mechanical Engineer Glen Guzik (NASA/ETD) • Lead Electrical Engineer – Andrew Bracey (NASA/ETD) • Lead Structural Engineer – TBD (Contractor) • Design, Analysis, and Modeling Support • Danny Allgood (NASA/ETD) • Richard Wear (NASA/ETD) • Daniel Jones (NASA/ETD) • Ke Nguyen (NASA/ETD) • Jody Woods (NASA/ETD) • Test Operations Support • Test Conductor – TBD (NASA/ETD) • Lead Mechanical Engineer, Andy Guymon (NASA/ETD) • Lead Electrical Engineer, Arron Head (NASA/ETD) • Lead S&MA – TBD (NASA/S&MA) • Business Manager – TBD • Project Scheduler – Lisa Ladner (TBD) • Hydrogen Wave Heater Development Liaison – Larry Dequay (NASA/ETD) • EUS Project Liaison – Chip Ellis, EUS Project Manager (NASA/ETD) 27

Nonnuclear Subscale RECS Test Project at E-3 Coordinating with EUS Diffuser Development Testing • Schedule is such that there should be no interference with test activities. . . EUS Diffuser Subscale RECS EUS Diffuser Other NTP Subscale Testing …. However, retesting is not unusual in the diffuser development business… • Subscale RECS Design Considerations: • Layout facility elements to reduce potential interferences • Modularity and portability to facilitate dismantling and reinstallation to minimize down time • “Relocatability” of test facility elements is a design consideration should conflicts occur 28

Nonnuclear Subscale RECS Test Project at E-3 The Bigger Picture 29