Lawrence Livermore National Labs Capstone Project
Overview
As part of my Capstone Project for UC Davis I worked on a Pressure Testing Station for Lawrence Livermore National Labs. Our system tested their warm targets in a few different ways including Max Shot, Helium Leak Detection, and Rate of Fall leak detection.
Links to some of the final design package. Because this was a Capstone Project I can share a lot about this project. Feel free to click through. The P&ID was one of my major contributions to the project and took many weeks of revisions.
Links:
Categories
Nuclear
Pressure Instruments
Date
Sep 2022
-
May 2025
Quarter Review
The main goal of this project is to create a system that can test if Nuclear Fusion targets will leak or rupture under specific pressures. This is a crucial step before the targets are used in the National Ignition Facility (NIF), where they face even higher pressures during experiments. Our station aims to operate at higher pressures than current systems, offer two methods for leak recording, and improve the overall user experience for technicians to minimize errors.
A significant portion of our recent efforts has focused on finalizing the Piping and Instrumentation Diagram (P&ID). This diagram is essentially the blueprint for all the piping, valves, and sensors in our system. We've gone through several iterations, incorporating feedback from LLNL to ensure the layout allows for all necessary testing procedures. The P&ID is designed to handle pressures from 0 to 300 PSI and allows for both Rate of Fall (ROF) and helium leak detection tests in a single station. We've carefully selected components like Swagelok fittings to ensure leak-tight connections, which is critical for accurate measurements. The P&ID also includes features to test various target types, including those with single or multiple gas lines, and incorporates safety measures like pressure relief valves.
Concurrently, we've developed the Frame that will house all the subsystems. A primary consideration here was the technician's experience and safety. The frame is constructed using 8020 aluminum extrusions, allowing for flexibility in mounting components and future upgrades. We've enclosed the testing area with polycarbonate panels for visibility and impact resistance, and to prevent particulates from easily entering. The design allows for easy access to components from multiple sides, even if the unit is placed against a wall. The base of the frame is made of steel to provide stability and prevent tipping, and it includes space for equipment like the leak detector. We've also incorporated a rail system for the test chamber, inspired by existing LLNL systems, to guide the chamber during target installation, minimizing the risk of damaging the fragile targets. This can also be upgraded with a linear actuator for automated movement.
While I've focused on the P&ID and Frame, my teammates have been diligently working on the other critical subsystems. This includes the detailed design of the Chamber itself, which houses the target during testing and must maintain a vacuum. The Electronics subsystem, another area of their focus, is responsible for data acquisition from sensors and controlling any automated components. They are also designing the code required to obtain sensor data and display it to a custom GUI.
The P&ID and Frame I've designed, alongside the subsystems being developed by my teammates, are key steps toward creating a robust and user-friendly testing station. Next up, our team will be focusing on benchtop testing and simulations to validate and further refine all aspects of the design.
Lawrence Livermore National Labs Capstone Project
Overview
As part of my Capstone Project for UC Davis I worked on a Pressure Testing Station for Lawrence Livermore National Labs. Our system tested their warm targets in a few different ways including Max Shot, Helium Leak Detection, and Rate of Fall leak detection.
Links to some of the final design package. Because this was a Capstone Project I can share a lot about this project. Feel free to click through. The P&ID was one of my major contributions to the project and took many weeks of revisions.
Links:
Categories
Nuclear
Pressure Instruments
Date
Sep 2022
-
May 2025
Quarter Review
The main goal of this project is to create a system that can test if Nuclear Fusion targets will leak or rupture under specific pressures. This is a crucial step before the targets are used in the National Ignition Facility (NIF), where they face even higher pressures during experiments. Our station aims to operate at higher pressures than current systems, offer two methods for leak recording, and improve the overall user experience for technicians to minimize errors.
A significant portion of our recent efforts has focused on finalizing the Piping and Instrumentation Diagram (P&ID). This diagram is essentially the blueprint for all the piping, valves, and sensors in our system. We've gone through several iterations, incorporating feedback from LLNL to ensure the layout allows for all necessary testing procedures. The P&ID is designed to handle pressures from 0 to 300 PSI and allows for both Rate of Fall (ROF) and helium leak detection tests in a single station. We've carefully selected components like Swagelok fittings to ensure leak-tight connections, which is critical for accurate measurements. The P&ID also includes features to test various target types, including those with single or multiple gas lines, and incorporates safety measures like pressure relief valves.
Concurrently, we've developed the Frame that will house all the subsystems. A primary consideration here was the technician's experience and safety. The frame is constructed using 8020 aluminum extrusions, allowing for flexibility in mounting components and future upgrades. We've enclosed the testing area with polycarbonate panels for visibility and impact resistance, and to prevent particulates from easily entering. The design allows for easy access to components from multiple sides, even if the unit is placed against a wall. The base of the frame is made of steel to provide stability and prevent tipping, and it includes space for equipment like the leak detector. We've also incorporated a rail system for the test chamber, inspired by existing LLNL systems, to guide the chamber during target installation, minimizing the risk of damaging the fragile targets. This can also be upgraded with a linear actuator for automated movement.
While I've focused on the P&ID and Frame, my teammates have been diligently working on the other critical subsystems. This includes the detailed design of the Chamber itself, which houses the target during testing and must maintain a vacuum. The Electronics subsystem, another area of their focus, is responsible for data acquisition from sensors and controlling any automated components. They are also designing the code required to obtain sensor data and display it to a custom GUI.
The P&ID and Frame I've designed, alongside the subsystems being developed by my teammates, are key steps toward creating a robust and user-friendly testing station. Next up, our team will be focusing on benchtop testing and simulations to validate and further refine all aspects of the design.
Lawrence Livermore National Labs Capstone Project
Overview
As part of my Capstone Project for UC Davis I worked on a Pressure Testing Station for Lawrence Livermore National Labs. Our system tested their warm targets in a few different ways including Max Shot, Helium Leak Detection, and Rate of Fall leak detection.
Links to some of the final design package. Because this was a Capstone Project I can share a lot about this project. Feel free to click through. The P&ID was one of my major contributions to the project and took many weeks of revisions.
Links:
Categories
Nuclear
Pressure Instruments
Date
Sep 2022
-
May 2025
Quarter Review
The main goal of this project is to create a system that can test if Nuclear Fusion targets will leak or rupture under specific pressures. This is a crucial step before the targets are used in the National Ignition Facility (NIF), where they face even higher pressures during experiments. Our station aims to operate at higher pressures than current systems, offer two methods for leak recording, and improve the overall user experience for technicians to minimize errors.
A significant portion of our recent efforts has focused on finalizing the Piping and Instrumentation Diagram (P&ID). This diagram is essentially the blueprint for all the piping, valves, and sensors in our system. We've gone through several iterations, incorporating feedback from LLNL to ensure the layout allows for all necessary testing procedures. The P&ID is designed to handle pressures from 0 to 300 PSI and allows for both Rate of Fall (ROF) and helium leak detection tests in a single station. We've carefully selected components like Swagelok fittings to ensure leak-tight connections, which is critical for accurate measurements. The P&ID also includes features to test various target types, including those with single or multiple gas lines, and incorporates safety measures like pressure relief valves.
Concurrently, we've developed the Frame that will house all the subsystems. A primary consideration here was the technician's experience and safety. The frame is constructed using 8020 aluminum extrusions, allowing for flexibility in mounting components and future upgrades. We've enclosed the testing area with polycarbonate panels for visibility and impact resistance, and to prevent particulates from easily entering. The design allows for easy access to components from multiple sides, even if the unit is placed against a wall. The base of the frame is made of steel to provide stability and prevent tipping, and it includes space for equipment like the leak detector. We've also incorporated a rail system for the test chamber, inspired by existing LLNL systems, to guide the chamber during target installation, minimizing the risk of damaging the fragile targets. This can also be upgraded with a linear actuator for automated movement.
While I've focused on the P&ID and Frame, my teammates have been diligently working on the other critical subsystems. This includes the detailed design of the Chamber itself, which houses the target during testing and must maintain a vacuum. The Electronics subsystem, another area of their focus, is responsible for data acquisition from sensors and controlling any automated components. They are also designing the code required to obtain sensor data and display it to a custom GUI.
The P&ID and Frame I've designed, alongside the subsystems being developed by my teammates, are key steps toward creating a robust and user-friendly testing station. Next up, our team will be focusing on benchtop testing and simulations to validate and further refine all aspects of the design.
