Category Archives: design

Reinforcement ensures long-term structural integrity

Last month when I was in Taiwan [see ‘Ancient Standards‘ on January 29th, 2020] , I visited Kuosheng Nuclear Power Plant which has a pair of boiling water reactors that each generate 986 MWe, or between them about 7% of Taiwan’s electricity.  The power station is approaching the end of its licensed life in around 2023 after being constructed in 1978 and delivering electricity commercially for about 40 years, since the early 1980’s.  There is an excellent exhibition centre at the power station that includes the life-size mock-up of the reinforcement rods in the concrete of the reactors shown in the photograph.  I am used to seeing reinforcing bar, or rebar as it is known, between 6 to 12mm in diameter on building site, but I had never seen any of this diameter (about 40 to 50mm diameter) or in such a dense grid.  On the other hand, we are not building any nuclear power stations in the UK at the moment so there aren’t many opportunities to see closeup the scale of structure required.

When seeing nothing is a success

In November I went to Zurich twice: once for the workshop that I wrote about last week [see ‘Fake facts and untrustworthy predictions’ on December 4th, 2019]; and, a second time for a progress meeting of the DIMES project [see ‘Finding DIMES’ on February 6th, 2019].  The progress meeting went well.  The project is on schedule and within budget. So, everyone is happy and you are wondering why I am writing about it.  It was what our team was doing around the progress meeting that was exciting.  A few months ago, Airbus delivered a section of an A320 wing to the labs of EMPA who are our project partner in Switzerland, and the team at EMPA has been rigging the wing section for a simple bending test so that we can use it to test the integrated measurement system which we are developing in the DIMES project [see ‘Joining the dots’ on July 10th, 2019].  Before and after the meeting, partners from EMPA, Dantec Dynamics GmbH, Strain Solutions Ltd and my group at the University of Liverpool were installing our prototype systems to monitor the condition of the wing when we apply bending loads to it.  There is some pre-existing damage in the wing that we hope will propagate during the test allowing us to track it with our prototype systems using visible and infra-red spectrum cameras as well as electrical and optical sensors.  The data that we collect during the test will allow us to develop our data processing algorithms and, if necessary, refine the system design.  The final stage of the DIMES project will involve installing a series of our systems in a complete wing undergoing a structural test in the new Airbus Wing Integration Centre (AWIC) in Filton, near Bristol in the UK.  The schedule is ambitious because we will need to install the sensors for our systems in the wing in the first quarter of next year, probably before we have finished all of the tests in EMPA.  However, the test in Bristol probably will not start until the middle of 2020, by which time we will have refined our algorithm for data processing and be ready for the deluge of data that we are likely to receive from the test at Airbus.  The difference between the two wing tests besides the level of maturity of our measurement system, is that no damage should be detected in the wing at Airbus whereas there will be detectable damage in the wing section in EMPA.  So, a positive result will be a success at EMPA but a negative result, i.e. no damage detected, will be a success at Airbus.

The DIMES project has received funding from the Clean Sky 2 Joint Undertaking under the European Union’s Horizon 2020 research and innovation programme under grant agreement No. 820951.

 

The opinions expressed in this blog post reflect only the author’s view and the Clean Sky 2 Joint Undertaking is not responsible for any use that may be made of the information it contains.

Thought leadership in fusion engineering

The harnessing of fusion energy has become something of a holy grail – sought after by many without much apparent progress.  It is the energy process that ‘powers’ the stars and if we could reproduce it on earth in a controlled environment then it would offer almost unlimited energy with very low environmental costs.  However, understanding the science is an enormous challenge and the engineering task to design, build and operate a fusion-fuelled power station is even greater.  The engineering difficulties originate from the combination of two factors: the emergent behaviour present in the complex system and that it has never been done before.  Engineering has achieved lots of firsts but usually through incremental development; however, with fusion energy it would appear that it will only work when all of the required conditions are present.  In other words, incremental development is not viable and we need everything ready before flicking the switch.  Not surprisingly, engineers are cautious about flicking switches when they are not sure what will happen.  Yet, the potential benefits of getting it right are huge; so, we would really like to do it.  Hence, the holy grail status: much sought after and offering infinite abundance.

Last week I joined the search, or at least offered guidance to those searching, by publishing an article in Royal Society Open Science on ‘An integrated digital framework for the design, build and operation of fusion power plants‘.  Working with colleagues at the Culham Centre for Fusion Energy, Richard Taylor and I have taken our earlier work on an integrated nuclear digital environment for the nuclear energy using fission [see ‘Enabling or disruptive technology for nuclear engineering?‘ on january 28th, 2015] and combined it with the hierarchical pyramid of testing and simulation used in the aerospace industry [see ‘Hierarchical modelling in engineering and biology‘ on March 14th, 2018] to create a framework that can be used to guide the exploration of large design domains using computational models within a distributed and collaborative community of engineers and scientists.  We hope it will shorten development times, reduce design and build costs, and improve credibility, operability, reliability and safety.  It is a long list of potential benefits for a relatively simple idea in a relatively short paper (only 12 pages).  Follow the link to find out more – it is an open access paper, so it’s free.

References

Patterson EA, Taylor RJ & Bankhead M, A framework for an integrated nuclear digital environment, Progress in Nuclear Energy, 87:97-103, 2016.

Patterson EA, Purdie S, Taylor RJ & Waldon C, An integrated digital framework for the design, build and operation of fusion power plants, Royal Society Open Science, 6(10):181847, 2019.

On the trustworthiness of multi-physics models

I stayed in Sheffield city centre a few weeks ago and walked past the standard measures in the photograph on my way to speak at a workshop.  In the past, when the cutlery and tool-making industry in Sheffield was focussed around small workshops, or little mesters, as they were known, these standards would have been used to check the tools being manufactured.  A few hundred years later, the range of standards in existence has extended far beyond the weights and measures where it started, and now includes standards for processes and artefacts as well as for measurements.  The process of validating computational models of engineering infrastructure is moving slowly towards establishing an internationally recognised standard [see two of my earliest posts: ‘Model validation‘ on September 18th, 2012 and ‘Setting standards‘ on January 29th, 2014].  We have guidelines that recommend approaches for different parts of the validation process [see ‘Setting standards‘ on January 29th, 2014]; however, many types of computational model present significant challenges when establishing their reliability [see ‘Spatial-temporal models of protein structures‘ on March 27th, 2019].  Under the auspices of the MOTIVATE project, we are gathering experts in Zurich on November 5th, 2019 to discuss the challenges of validating multi-physics models, establishing credibility and the future use of data from experiments.  It is the fourth in a series of workshops held previously in Shanghai, London and Munich.  For more information and to register follow this link. Come and join our discussions in one of my favourite cities where we will be following ‘In Einstein’s footprints‘ [posted on February 27th, 2019].

The MOTIVATE project has received funding from the Clean Sky 2 Joint Undertaking under the European Union’s Horizon 2020 research and innovation programme under grant agreement No. 754660.

The opinions expressed in this blog post reflect only the author’s view and the Clean Sky 2 Joint Undertaking is not responsible for any use that may be made of the information it contains.