issue Statement: A Sandia National Laboratories Member of the Workforce (MOW) experienced contact with electrical energy while performing work on an oil filter pump electrical system in the al wind turbine nacelle at Sandia National Laboratories Scaled Wind Turbine Facility (SWiFT). The Department of Energy (DOE) Sandia National Laboratories (SNL) Scaled Wind Farm Technology (SWiFT) facility does research and development (R&D) work in collaboration with Texas Tech University. The SWiFT facility includes three turbines for performing wind plant and turbine technology research in support of DOE's Wind Energy Technology Office. The current work ongoing at the site is primarily related to commissioning the three turbines to support ongoing DOE customer needs and requests. It was during the performance of commissioning tests of the hydraulic systems in the a1 turbine that a Sandia MOW experienced contact with electrical energy. There were multiple root and contributing causes that ultimately resulted in the electrical energy contact. These causes are summarized and aligned to their corrective actions in the corrective action plan table provided in Section 7(c). The purpose of this narrative section is to provide additional information and context
Niobium doped PZT 95/5 (lead zirconate-lead titanate) is the material used in voltage bars for all ferroelectric neutron generator power supplies. In June of 1999, the transfer and scale-up of the Sandia Process from Department 1846 to Department 14192 was initiated. The laboratory-scale process of 1.6 kg has been successfully scaled to a production batch quantity of 10 kg. This report documents efforts to characterize and optimize the production-scale process utilizing Design of Experiments methodology. Of the 34 factors identified in the powder preparation sub-process, 11 were initially selected for the screening design. Additional experiments and safety analysis subsequently reduced the screening design to six factors. Three of the six factors (Milling Time, Media Size, and Pyrolysis Air Flow) were identified as statistically significant for one or more responses and were further investigated through a full factorial interaction design. Analysis of the interaction design resulted in developing models for Powder Bulk Density, Powder Tap Density, and +20 Mesh Fraction. Subsequent batches validated the models. The initial baseline powder preparation conditions were modified, resulting in improved powder yield by significantly reducing the +20 mesh waste fraction. Response variation analysis indicated additional investigation of the powder preparation sub-process steps was necessary to identify and reduce the sources of variation to further optimize the process.
The Materials Chemistry Department 1846 has developed a lab-scale chem-prep process for the synthesis of PNZT 95/5, referred to as the ''SP'' process (Sandia Process). This process (TSP) has been successfully transferred to and scaled-up by Department 14192 (Ceramics and Glass Department), producing the larger quantities of PZT powder required to meet the future supply needs of Sandia for neutron generator production. The particle size distributions of TSP powders routinely have been found to contain a large particle size fraction that was absent in development (SP) powders. This SAND report documents experimental studies focused on characterizing these particles and assessing their potential impact on material performance. To characterize these larger particles, fractionation of several TSP powders was performed. The ''large particle size fractions'' obtained were characterized by particle size analysis, SEM, and ICP analysis and incorporated into compacts and sintered. Large particles were found to be very similar in structure and composition as the bulk of the powder. Studies showed that the large-size fractions of the powders behave similarly to the non-fractionated powder with respect to the types of microstructural features once sintered. Powders were also compared that were prepared using different post-synthesis processing (i.e. differences in precipitate drying). Results showed that these powders contained different amounts and sizes of porous inclusions when sintered. How this affects the functional performance of the PZT 95/5 material is the subject of future investigations.
The Materials Chemistry Department 1846 has developed a lab-scale chem-prep process for the synthesis of PNZT 95/5, a ferroelectric material that is used in neutron generator power supplies. This process (Sandia Process, or SP) has been successfully transferred to and scaled by Department 14192 (Ceramics and Glass Department), (Transferred Sandia Process, or TSP), to meet the future supply needs of Sandia for its neutron generator production responsibilities. In going from the development-size SP batch (1.6 kg/batch) to the production-scale TSP powder batch size (10 kg/batch), it was important that it be determined if the scaling process caused any ''performance-critical'' changes in the PNZT 95/5 being produced. One area where a difference was found was in the particle size distributions of the calcined PNZT powders. Documented in this SAND report are the results of an experimental study to determine the origin of the differences in the particle size distribution of the SP and TSP powders.