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At least 217 records · Page 12

All sources NASA NTRS DOE OSTI

DOE OSTI2021

The Marine and Hydrokinetic ToolKit (MHKiT) for Data Quality Control and Analysis [Slides]

The ability to collect, ingest, condition, reduce, quality control, process, visualize, and store data in a standardized way is critical at all stages of Marine Energy (ME) research and technology/project development. MHKiT is an open-source, standardized suite of ME data processing functions that provides the ability to ingest, condition, reduce, quality control, process, visualize and store ME data. MHKiT is developed in both Python and Matlab.

16 TIDAL AND WAVE POWER↗

DOE OSTI2015

Selective catalytic reduction system and process for control of NO.sub.x emissions in a sulfur-containing gas stream

An exhaust gas treatment process, apparatus, and system for reducing the concentration of NOx, CO and hydrocarbons in a gas stream, such as an exhaust stream (29), via selective catalytic reduction with ammonia is provided. The process, apparatus and system include a catalytic bed (32) having a reducing only catalyst portion (34) and a downstream reducing-plus-oxidizing portion (36). Each portion (34, 36) includes an amount of tungsten. The reducing-plus-oxidizing catalyst portion (36) advantageously includes a greater amount of tungsten than the reducing catalyst portion (36) to markedly limit ammonia salt formation.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2017

Nonlinear model predictive control for chemical looping process

A control system for optimizing a chemical looping ("CL") plant includes a reduced order mathematical model ("ROM") that is designed by eliminating mathematical terms that have minimal effect on the outcome. A non-linear optimizer provides various inputs to the ROM and monitors the outputs to determine the optimum inputs that are then provided to the CL plant. An estimator estimates the values of various internal state variables of the CL plant. The system has one structure adapted to control a CL plant that only provides pressure measurements in the CL loops A and B, a second structure adapted to a CL plant that provides pressure measurements and solid levels in both loops A, and B, and a third structure adapted to control a CL plant that provides full information on internal state variables. A final structure provides a neural network NMPC controller to control operation of loops A and B.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2012

Reduction in Fabrication Costs of Gas Diffusion Layers

Ballard Material Products (BMP) performed a pre-design technical and cost analysis of state of the art production technologies feasible for high volume GDL manufacturing. Based upon criteria that also included environmental health and safety, customer quality requirements, and future needs, BMP selected technologies that can be integrated into its current manufacturing process. These selections included Many-At-A-Time (MAAT) coating and continuous mixing technologies, as well as various on-line process control tools. These processes have allowed BMP to produce high performance GDLs at lower cost for near-term markets, as well as to define the inputs needed to develop a conceptual Greenfield facility to meet the cost targets for automotive volumes of 500,000 vehicles per year.

08 HYDROGEN↗

DOE OSTI2012

A Robust Infrastructure Design for Gas Centrifuge Enrichment Plant Unattended Online Enrichment Monitoring

An online enrichment monitor (OLEM) is being developed to continuously measure the relative isotopic composition of UF6 in the unit header pipes of a gas centrifuge enrichment plant (GCEP). From a safeguards perspective, OLEM will provide early detection of a facility being misused for production of highly enriched uranium. OLEM may also reduce the number of samples collected for destructive assay and if coupled with load cell monitoring can provide isotope mass balance verification. The OLEM design includes power and network connections for continuous monitoring of the UF6 enrichment and state of health of the instrument. Monitoring the enrichment on all header pipes at a typical GCEP could require OLEM detectors on each of the product, tails, and feed header pipes. If there are eight process units, up to 24 detectors may be required at a modern GCEP. Distant locations, harsh industrial environments, and safeguards continuity of knowledge requirements all place certain demands on the network robustness and power reliability. This paper describes the infrastructure and architecture of an OLEM system based on OLEM collection nodes on the unit header pipes and power and network support nodes for groupings of the collection nodes. A redundant, self-healing communications network, distributed backup power, and a secure communications methodology. Two candidate technologies being considered for secure communications are the Object Linking and Embedding for Process Control Unified Architecture cross-platform, service-oriented architecture model for process control communications and the emerging IAEA Real-time And INtegrated STream-Oriented Remote Monitoring (RAINSTORM) framework to provide the common secure communication infrastructure for remote, unattended monitoring systems. The proposed infrastructure design offers modular, commercial components, plug-and-play extensibility for GCEP deployments, and is intended to meet the guidelines and requirements for unattended and remotely monitored safeguards systems.

On Line Enrichment Monitor GCEP↗

DOE OSTI2013

Computational Tools to Accelerate Commercial Development

The goals of the work reported are: to develop new computational tools and models to enable industry to more rapidly develop and deploy new advanced energy technologies; to demonstrate the capabilities of the CCSI Toolset on non-proprietary case studies; and to deploy the CCSI Toolset to industry. Challenges of simulating carbon capture (and other) processes include: dealing with multiple scales (particle, device, and whole process scales); integration across scales; verification, validation, and uncertainty; and decision support. The tools cover: risk analysis and decision making; validated, high-fidelity CFD; high-resolution filtered sub-models; process design and optimization tools; advanced process control and dynamics; process models; basic data sub-models; and cross-cutting integration tools.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2013

Computational Tools for Accelerating Carbon Capture Process Development

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2014

Secure control systems with application to cyber-physical systems

Control systems are computer-based systems with networked units consisting of sensors, actuators, control processing units, and communication devices. The role of control system is to interact, monitor, and control physical processes. Reactive power control is a fundamental issue in ensuring the security of the power network. It is claimed that Synchronous Condensers (SC) have been used at both distribution and transmission voltage levels to improve stability and to maintain voltages within desired limits under changing load conditions and contingency situations. Performance of PI controller corresponding to various tripping faults are analyzed for SC systems. Most of the eort in protecting these systems has been in protection against random failures or reliability. However, besides failures these systems are subject to various signal attacks for which new analysis are discussed here. When a breach does occur, it is necessary to react in a time commensurate with the physical dynamics of the system as it responds to the attack. Failure to act swiftly enough may result in undesirable, and possibly irreversible, physical eects. Therefore, it is meaningful to evaluate the security of a cyber-physical system, especially to protect it from cyber-attack. Illustrative numerical examples are provided together with an application to the SC systems.

Dong, Jin↗

DOE OSTI2016

TU-FG-201-09: Predicting Accelerator Dysfunction

Purpose: To develop an integrated statistical process control (SPC) framework using digital performance and component data accumulated within the accelerator system that can detect dysfunction prior to unscheduled downtime. Methods: Seven digital accelerators were monitored for twelve to 18 months. The accelerators were operated in a ‘run to failure mode’ with the individual institutions determining when service would be initiated. Institutions were required to submit detailed service reports. Trajectory and text log files resulting from a robust daily VMAT QA delivery were decoded and evaluated using Individual and Moving Range (I/MR) control charts. The SPC evaluation was presented in a customized dashboard interface that allows the user to review 525 monitored parameters (480 MLC parameters). Chart limits were calculated using a hybrid technique that includes the standard SPC 3σ limits and an empirical factor based on the parameter/system specification. The individual (I) grand mean values and control limit ranges of the I/MR charts of all accelerators were compared using statistical (ranked analysis of variance (ANOVA)) and graphical analyses to determine consistency of operating parameters. Results: When an alarm or warning was directly connected to field service, process control charts predicted dysfunction consistently on beam generation related parameters (BGP)– RF Driver Voltage, Gun Grid Voltage, and Forward Power (W); beam uniformity parameters – angle and position steering coil currents; and Gantry position accuracy parameter: cross correlation max-value. Control charts for individual MLC – cross correlation max-value/position detected 50% to 60% of MLCs serviced prior to dysfunction or failure. In general, non-random changes were detected 5 to 80 days prior to a service intervention. The ANOVA comparison of BGP determined that each accelerator parameter operated at a distinct value. Conclusion: The SPC framework shows promise. Long term monitoring coordinated with service will be required to definitively determine the effectiveness of the model. Varian Medical System, Inc. provided funding in support of the research presented.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2019

Maintenance Plan for the Performance Assessments and Composite Analyses for the Area 3 and Area 5 Radioactive Waste Management Sites at the Nevada National Security Site (Rev.3)

U.S. Department of Energy (DOE) Order 435.1, Radioactive Waste Management, requires that performance assessments (PAs) and composite analyses (CAs) for low-level radioactive waste (LLW) disposal facilities be maintained by the responsible field office. This plan describes the activities performed to maintain the PA and the CA for the Area 3 and Area 5 Radioactive Waste Management Sites (RWMSs) at the Nevada National Security Site (NNSS). The plan is based on DOE Order 435.1 Radioactive Waste Management (DOE 2007), DOE Manual 435.1-1, Radioactive Waste Management Manual (DOE 2011), and DOE Standard DOE-STD-5002-2017, Disposal Authorization Statement and Tank Closure Documentation (DOE 2017). The facility’s Disposal Authorization Statement (DAS) specifies conditions for the continuing operation of a LLW facility. The DAS is issued based on a review of the facility's PA, CA, the maintenance plan, preliminary closure plan, and preliminary monitoring plan. The DAS specifies the limits and conditions on construction, design, operations, and closure of the low-level waste facility based on these reviews. The Maintenance Plan uses an Unreviewed Disposal Question (UDQ)/Unreviewed Composite Analysis Question (UCAQ) change control process to identify, evaluate, and control planned or discovered changes affecting the PA, CA, DAS, or other documents composing the Radioactive Waste Management Basis (RWMB). The UDQ/UCAQ process uses the PA and CA GoldSim models to calculate updated results, assess the significance of changes, and to assess the need to revise the PA, CA, or DAS. In addition to the change control process, the Maintenance Plan requires an annual review of all changes and an annual assessment of the need to revise RWMB documents, plans, and programs. The cumulative effect of all changes is assessed annually by preparing a revised PA and CA baseline model that is used to update PA and CA results. The updated results are used to assess compliance with the PA performance objectives and the CA dose constraint, and to assess the need to revise the PAs, CAs, and other documents, plans, and programs supporting the RWMB. An Annual Summary Report documenting the results and conclusions of the annual review is prepared and submitted to DOE.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2011

Devices Materials and Processes for Nanoelectronics: Characterization with Advanced X-Ray Techniques Using Lab-Based and Synchrotron Radiation Sources

Future nanoelectronics manufacturing at extraordinary length scales, new device structures, and advanced materials will provide challenges to process development and engineering but also to process control and physical failure analysis. Advanced X-ray techniques, using lab systems and synchrotron radiation sources, will play a key role for the characterization of thin films, nanostructures, surfaces, and interfaces. The development of advanced X-ray techniques and tools will reduce risk and time for the introduction of new technologies. Eventually, time-to-market for new products will be reduced by the timely implementation of the best techniques for process development and process control. The development and use of advanced methods at synchrotron radiation sources will be increasingly important, particularly for research and development in the field of advanced processes and new materials but also for the development of new X-ray components and procedures. The application of advanced X-ray techniques, in-line, in out-of-fab analytical labs and at synchrotron radiation sources, for research, development, and manufacturing in the nanoelectronics industry is reviewed. The focus of this paper is on the study of nanoscale device and on-chip interconnect materials, and materials for 3D IC integration as well.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2016

Processing temperature control of a diketopyrrolopyrrole- alt -thieno[2,3- b ]thiophene polymer for high-mobility thin-film transistors and polymer solar cells with high open-circuit voltages

Here, we synthesized a planar pDPPTTi-OD polymer based on diketopyrrolopyrrole (DPP) and thieno [2,3- b ] thiophene (TTi) and investigated the electrical properties of the pDPPTTi-OD polymer. pDPPTTi-OD films displayed a low optical bandgap of 1.57 eV, and HOMO and LUMO levels of –5.40 and –3.74 eV, respectively. The 150°C-annealed pDPPTTi-OD films showed a high hole mobility of 0.16 cm 2 V –1 s –1 in organic thin-film transistor (OTFT) devices. The photovoltaic properties of polymer solar cells (PSCs) incorporating the pDPPTTi-OD were also measured. A pDPPTTi-OD:PC 71 BM blend film was spin-coated at 25, 70 and 90 °C. High-temperature processing significantly improved the power conversion efficiency of PSCs by effectively reducing the PC 71 BM domain sizes, which improved the miscibility between pDPPTTi-OD and PC 71 BM. Furthermore, this work demonstrated that the TTi moiety is a useful donor building block for high-performance D–A type polymers in OTFTs and PSCs, and that processing temperatures should be controlled to fully realize the materials' beneficial intrinsic properties.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Testing of the Defense Waste Processing Facility Cold Chemical Dissolution Method in Sludge Batch 9 Qualification

For each sludge batch that is processed in the Defense Waste Processing Facility (DWPF), the Savannah River National Laboratory (SRNL) tests the applicability of the digestion methods used by the DWPF Laboratory for elemental analysis of Sludge Receipt and Adjustment Tank (SRAT) Receipt samples and SRAT Product process control samples. DWPF SRAT samples are typically dissolved using a method referred to as the DWPF Cold Chemical or Cold Chem Method (CC), (see DWPF Procedure SW4- 15.201). Testing indicates that the CC method produced mixed results. The CC method did not result in complete dissolution of either the SRAT Receipt or SRAT Product with some fine, dark solids remaining. However, elemental analyses did not reveal extreme biases for the major elements in the sludge when compared with analyses obtained following dissolution by hot aqua regia (AR) or sodium peroxide fusion (PF) methods. The CC elemental analyses agreed with the AR and PF methods well enough that it should be adequate for routine process control analyses in the DWPF after much more extensive side-by-side tests of the CC method and the PF method are performed on the first 10 SRAT cycles of the Sludge Batch 9 (SB9) campaign. The DWPF Laboratory should continue with their plans for further tests of the CC method during these 10 SRAT cycles.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Towards in-situ certification of additively manufactured parts: the vital roles of physics-based and data-driven models

Certifying additively manufactured (AM) parts in-situ at the completion of a build is an enticing prospect, as it can help reduce the high costs associated with post-build testing and evaluation. However, achieving this goal presents significant challenges that may keep it aspirational for the foreseeable future. Nonetheless, incremental progress can pave the way forward. A critical aspect of in-situ certification involves continuous quality checking due to the random nature of the AM process and the difficulties in detecting defects or anomalies once layers are built over. While real-time in-situ monitoring strategies assisted by machine learning (ML) play a pivotal role in auditing part quality, they must ideally be supported by real-time (or near real-time) adaptive process control enabled by ML-assisted decision-making. By analyzing in-situ monitoring data in real-time (or near real- time) to dynamically adjust manufacturing parameters, such intervention can ensure AM parts are built to meet stringent certification standards. This can be achieved virtually by using high-fidelity performance models for the physical testing and evaluation tasks. In this short editorial, we discuss the key contributions made by data-driven and physics-based models in providing intelligence to the monitoring and process control tasks underpinning in-situ certification and in the simulation of the build’s performance under test and service conditions. While our focus lies in metal AM, the concepts discussed here are also relevant to other AM processes.

: In-situ monitoring↗

DOE OSTI2016

SU-G-TeP4-07: Automatic EPID-Based 2D Measurement of MLC Leaf Offset as a Quality Control Tool

Purpose: The MLC dosimetric leaf gap (DLG) and transmission are measured parameters which impact the dosimetric accuracy of IMRT and VMAT plans. This investigation aims to develop an efficient and accurate routine constancy check of the physical DLG in two dimensions. Methods: The manufacturer’s recommended DLG measurement method was modified by using 5 fields instead of 11 and by utilizing the Electronic Portal Imaging Device (EPID). Validations were accomplished using an ion chamber (IC) in solid water and a 2D IC array. EPID data was collected for 6 months on multiple TrueBeam linacs using both Millennium and HD MLCs at 5 different clinics in an international consortium. Matlab code was written to automatically analyze the images and calculate the 2D results. Sensitivity was investigated by introducing deliberate leaf position errors. MLC calibration and initialization history was recorded to allow quantification of their impact. Results were analyzed using statistical process control (SPC). Results: The EPID method took approximately 5 minutes. Due to detector response, the EPID measured DLG and transmission differed from the IC values but were reproducible and consistent with changes measured using the ICs. For the Millennium MLC, the EPID measured DLG and transmission were both consistently lower than IC results. The EPID method was implemented as leaf offset and transmission constancy tests (LOC and TC). Based on 6 months of measurements, the initial leaf-specific action thresholds for changes from baseline were set to 0.1 mm. Upper and lower control limits for variation were developed for each machine. Conclusion: Leaf offset and transmission constancy tests were implemented on Varian HD and Millennium MLCs using an EPID and found to be efficient and accurate. The test is effective for monitoring MLC performance using dynamic delivery and performing process control on the DLG in 2D, thus enhancing dosimetric accuracy. This work was supported by a grant from Varian Medical Systems.

61 RADIATION PROTECTION AND DOSIMETRY↗

DOE OSTI2021

Overview of the Process Automation and Control Group (E-3) [Slides]

Process Automation and Control (E-3) is a part of the Weapons Associate Laboratory Directorate (DDW) which includes Weapons Engineering Directorate (WE) and the Engineering Technology and Design (E) Division. There are three teams: Fabrication and Assembly, Process Controls, and Automation and Robotics. After an overview of the group, information is provided about an internship and how to apply.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2021

Cyber-Physical System Implementation for Manufacturing With Analytics in the Cloud Layer

Effective and efficient modern manufacturing operations require the acceptance and incorporation of the fourth industrial revolution, also known as Industry 4.0. Traditional shop floors are evolving their production into smart factories. To continue this trend, a specific architecture for the cyber-physical system is required, as well as a systematic approach to automate the application of algorithms and transform the acquired data into useful information. This work makes use of an approach that distinguishes three layers that are part of the existing Industry 4.0 paradigm: edge, fog, and cloud. Each of the layers performs computational operations, transforming the data produced in the smart factory into useful information. Trained or untrained methods for data analytics can be incorporated into the architecture. A case study is presented in which a real-time statistical control process algorithm based on control charts was implemented. The algorithm automatically detects changes in the material being processed in a computerized numerical control (CNC) machine. The algorithm implemented in the proposed architecture yielded short response times. The performance was effective since it automatically adapted to the machining of aluminum and then detected when the material was switched to steel. The data were backed up in a database that would allow traceability to the line of g-code that performed the machining.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2019

A geometric approach for computing tolerance bounds for elastic functional data

We design an approach for constructing tolerance bounds for functional data with random warping variability. In particular, we define a generative, probabilistic model for the amplitude and phase components of such observations, which parsimoniously characterizes variability in the baseline data. Based on the proposed model, we define two different types of tolerance bounds that are able to measure both types of variability, and as a result, identify when the data has gone beyond the bounds of amplitude and/or phase. The first functional tolerance bounds are computed via a bootstrap procedure on the geometric space of amplitude and phase functions. The second functional tolerance bounds utilize functional Principal Component Analysis to construct a tolerance factor. Our report is motivated by two main applications: process control and disease monitoring. The problem of statistical analysis and modeling of functional data in process control is important in determining when a production has moved beyond a baseline. Moreover, in biomedical applications, doctors use long, approximately periodic signals (such as the electrocardiogram) to diagnose and monitor diseases. In this context, it is desirable to identify abnormalities in these signals. We additionally consider a simulated example to assess our approach and compare it to two existing methods.

97 MATHEMATICS AND COMPUTING↗