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DOE OSTI2025

Explainable discrepancy checker and diagnosis for digital Twin-based supervisory control system

By virtually representing a physical object and process, a digital twin (DT) enables optimal autonomous operations by combining classical and novel frameworks in sensors, state predictions, and multi-input/multi-output systems. A DT’s values depend on how well models estimate quantities of interest and on how uncertainty is handled. Moreover, DTs often combine physics-based and data-driven models with mixed fidelities, where classical uncertainty quantification (UQ) struggles with many sources of uncertainty and real-time constraints. Here, this work presents a UQ-based discrepancy checking and diagnosis tool for a DT-based supervisory control system. The tool is developed using metadata from an automated DT development process to learn correlations between sources of uncertainties and outcomes. During operation, it compares predictions with measurements, attributes discrepancies to dominant sources, and recommends parameter and configuration updates. We verify the workflow on a synthetic temperature-control problem and deploy it on a virtual Thermal Energy Delivery System, reducing mismatch and improving control robustness.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Method for Assessment of Security-Relevant Settings in Anomaly-Based Intrusion Detection for Industrial Control Systems

Ensuring the integrity of Ethernet-based networks is a challenging and constantly evolving domain. This problem is exacerbated for those operational technology (OT) networks supporting industrial control systems (ICS) since much of that equipment was originally designed to be on a network that was isolated and generally considered free of malefactors. Increasing pressure to bridge these systems with traditional information technology (IT) networks has introduced a bevy of new threats. In response, both academia and industry have responded with security solutions tailored to ICS environments. Deploying these protection systems often involves several configuration choices. While some of these choices are clear (e.g., block/enable protocol X) others are far more subjective (e.g. alert threshold == 3.43). Further complicating the situation, while often similar to IT networks, OT networks have unique challenges and characteristics that make the task of protecting them simultaneously more difficult and straight forward.Extant solutions for quantifying the relative security of intrusion detection systems fail to effectively support the operators of said systems with understanding the impact of various configuration changes. Further, they assume that the attacks are static and not subject to manipulation or alteration in the face of defenses. In this paper, we present a threat-based method for quantifying the relative impact of various security settings for intrusion detection systems (IDSs) within ICS environments. This method provides operational staff with a clear understanding of the relative impact of their settings and assumes that the attacks levied against them are dynamic. The model is described in detail, we apply the model to a synthetic data set, and discuss the inferences that can be made and what types of decisions they could be used to support.

Gillen, Rob↗

DOE OSTI2017

Guide for Cyber Assessment of Industrial Control Systems Field Devices

Programmable logic controllers (PLCs) and other field devices are important components of many weapons platforms, including vehicles, ships, radar systems, etc. Many have significant cyber vulnerabilities that lead to unacceptable risk. Furthermore, common procedures used during Operational Test and Evaluation (OT&E) may unexpectedly lead to unsafe or severe impacts for the field devices or the underlying physical process. This document describes an assessment methodology that addresses vulnerabilities, mitigations, and safe OT&E.

42 ENGINEERING↗

DOE OSTI2023

Adaptive Cyber-Physical Resilience for Building Control Systems

The main goal of the project is to develop an AI-based process layer cybersecurity suite for detection, isolation and mitigation of cyber-attack effects on operation of building energy management systems (BEMS). The following constituent key technologies were developed under the program towards fulfilling the program objectives: (1) developed a high fidelity BEMS testbed for generation of training data and validation of developed technologies; (2) developed a physics informed ML based attack detection and localization module (ADL) capable of detecting high impact stealthy attacks (HISA - attacks causing 30% energy utilization but no immediate visible impact otherwise) with 98% accuracy; (3) developed a methodology to determine ’representative days’ to limit the data required for training; (4) developed a virtual sensing system that can reconstruct affected sensors with 10% error for the same HISA set; (5) developed a resilient model predictive control system that can continue operation of the BEMS without jeopardizing stability for the HISA set; and (6) integrated and deployed all the constituent modules and demonstrated the efficacy of the technology in real-time in a hardware in loop simulation.

42 ENGINEERING↗

DOE OSTI2017

Nonlinear Dynamic Model-Based Multiobjective Sensor Network Design Algorithm for a Plant with an Estimator-Based Control System

Here, a novel sensor network design (SND) algorithm is developed for maximizing process efficiency while minimizing sensor network cost for a nonlinear dynamic process with an estimator-based control system. The multiobjective optimization problem is solved following a lexicographic approach where the process efficiency is maximized first followed by minimization of the sensor network cost. The partial net present value, which combines the capital cost due to the sensor network and the operating cost due to deviation from the optimal efficiency, is proposed as an alternative objective. The unscented Kalman filter is considered as the nonlinear estimator. The large-scale combinatorial optimization problem is solved using a genetic algorithm. The developed SND algorithm is applied to an acid gas removal (AGR) unit as part of an integrated gasification combined cycle (IGCC) power plant with CO 2 capture. Due to the computational expense, a reduced order nonlinear model of the AGR process is identified and parallel computation is performed during implementation.

Lexicographic optimization↗

DOE OSTI2023

Dynamic Model Agnostic Reliability Evaluation of Machine-Learning Models Integrated in Instrumentation & Control Systems

In recent years, the field of data-driven neural network-based machine learning (ML) algorithms has grown significantly and spurred research in its applicability to instrumentation and control systems. While they are promising in operational contexts, the trustworthiness of such algorithms is not adequately assessed. Failures of ML-integrated systems are poorly understood; the lack of comprehensive risk modeling can degrade the trustworthiness of these systems. In recent reports by the National Institute for Standards and Technology, trustworthiness in ML is a critical barrier to adoption and will play a vital role in intelligent systems' safe and accountable operation. Thus, in this work, we demonstrate a real-time model-agnostic method to evaluate the relative reliability of ML predictions by incorporating out-of-distribution detection on the training dataset. It is well documented that ML algorithms excel at interpolation (or near-interpolation) tasks but significantly degrade at extrapolation. This occurs when new samples are "far" from training samples. The method, referred to as the Laplacian distributed decay for reliability (LADDR), determines the difference between the operational and training datasets, which is used to calculate a prediction's relative reliability. LADDR is demonstrated on a feedforward neural network-based model used to predict safety significant factors during different loss-of-flow transients. LADDR is intended as a "data supervisor" and determines the appropriateness of well-trained ML models in the context of operational conditions. Ultimately, LADDR illustrates how training data can be used as evidence to support the trustworthiness of ML predictions when utilized for conventional interpolation tasks.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

An Integrated Framework for Risk Assessment of Safety-related Digital Instrumentation and Control Systems in Nuclear Power Plants: Methodology Refinement and Exploration

This report documents activities performed by Idaho National Laboratory (INL) during Fiscal Year (FY) 2023 for the U.S. Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program, Risk Informed Systems Analysis (RISA) Pathway, digital instrumentation and control (DI&C) risk assessment project. In FY 2019, the RISA Pathway initiated a project to develop a risk assessment strategy for delivering a technical basis to support effective, and secure DI&C technologies for digital upgrades/designs. A risk assessment-informed framework was proposed for this strategy, which aims to (1) provide a best-estimate, risk informed capability to quantitatively estimate the safety margin obtained from plant modernization, especially for safety-related DI&C systems, (2) support and supplement existing risk informed DI&C design guides by providing quantitative risk information and evidence, (3) offer a capability of design architecture evaluation of various DI&C systems, (4) assure the long-term safety and reliability of safety-related DI&C systems, and (5) reduce uncertainty in costs and support integration of DI&C systems in the plant. To achieve these technical goals, the LWRS-developed framework provides a means to address relevant technical issues by: (1) defining a risk informed analysis process for DI&C upgrade that integrates hazard analysis, reliability analysis, and consequence analysis, (2) applying risk informed tools to address common cause failures (CCFs) and quantify corresponding failure probabilities for DI&C technologies, particularly software CCFs, (3) evaluating the impact of digital failures at the component level, system level, and plant level, and (4) providing insights and suggestions on designs to manage the risks, thus to support the development and deployment of advanced DI&C technologies in nuclear power plants (NPPs). Adding diversity within a system or components is the primary means to eliminate and mitigate CCFs, but diversity also increases system complexity and may not address all sources of systematic failures. Optimization of diversity and redundancy applications for the safety-critical DI&C systems remains a challenge. To deal with the technical issues in addressing potential software CCFs in safety-related DI&C systems of NPPs and supporting relevant design optimization, the proposed framework provides: (a) A best-estimate, risk informed capability to address new technical digital issues quantitatively, focusing on software CCFs in safety-related DI&C systems of NPPs; (b) A common and a modularized platform for DI&C designers, software developers, cybersecurity analysts, and plant engineers to predict and prevent risk in the early design stage of DI&C systems; (c) Technical bases and risk informed insights to assist users address the risk informed alternatives for evaluation of CCFs in safety-related DI&C systems of NPPs; and (d) A risk informed tool that offers a capability of design architecture evaluation of various DI&C systems to support system design decisions in diversity and redundancy applications. The research and development efforts of this project in FY 2023 are focused on refining current methods on software CCF modeling and estimation and exploring additional innovative approaches to risk assessment of DI&C systems to enable a more comprehensive and complete assessment of various safety-related DI&C design architectures. The primary audience of this report are DI&C designers, engineers, and probabilistic risk assessment (PRA) practitioners. This includes stakeholders, such as the nuclear utilities and regulators who consider the deployment and upgrade of DI&C systems, DI&C software developers and reviewers, and cybersecurity specialists. It should be noted that all the analyses are performed for the demonstration of the methodology, not for the evaluation of an actual digital control system. Results are obtained based on limited design information and testing data.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

BOOSTR: A Dataset for Accelerator Control Systems

The Booster Operation Optimization Sequential Time-series for Regression (BOOSTR) dataset was created to provide a cycle-by-cycle time series of readings and settings from instruments and controllable devices of the Booster, Fermilab’s Rapid-Cycling Synchrotron (RCS) operating at 15 Hz. BOOSTR provides a time series from 55 device readings and settings that pertain most directly to the high-precision regulation of the Booster’s gradient magnet power supply (GMPS). To our knowledge, this is one of the first well-documented datasets of accelerator device parameters made publicly available. We are releasing it in the hopes that it can be used to demonstrate aspects of artificial intelligence for advanced control systems, such as reinforcement learning and autonomous anomaly detection.

Kafkes, Diana (ORCID:000000021716463X)↗

DOE OSTI2021

BOOSTR: A Dataset for Accelerator Control Systems

The Booster Operation Optimization Sequential Time-series for Regression (BOOSTR) dataset was created to provide a cycle-by-cycle time series of readings and settings from instruments and controllable devices of the Booster, Fermilab's Rapid-Cycling Synchrotron (RCS) operating at 15~Hz. BOOSTR provides a time series from 55 device readings and settings that pertain most directly to the high-precision regulation of the Booster's gradient magnet power supply (GMPS). To our knowledge, this is one of the first well-documented datasets of accelerator device parameters made publicly available. We are releasing it in the hopes that it can be used to demonstrate aspects of artificial intelligence for advanced control systems, such as reinforcement learning and autonomous anomaly detection.

43 PARTICLE ACCELERATORS↗

DOE OSTI2017

Integrated Measurement and Control System for SIF (IMACSS)

The foundation of our biosphere and civilization rests on the food and energy produced by plants using sunlight. Yet currently there is no commercially available technology that can measure, continuously and unattended, plant photosynthesis and physiological stresses in natural environments. To fill this commercial technology gap, a Sun-Induced chlorophyll Fluorescence (SIF) Auto-Measurement Equipment (FAME) that can be applied at scales of leaf, individual plant, or canopy in the field has been developed. The Integrated Measurement and Control System for SIF (IMACSS) is the software used to control the operation of the FAME. IMACSS is a datalogger-operated software which directly controls ALL FUNCTIONS of high-resolution spectrometers for SIF measurements - including the operation temperature and integration time of the Charge-Coupled Device (CCD) detectors of spectrometers, the opening and closing of internal shutter, setting and storing of radiance/irradiance calibration coefficients, wavelength calibration coefficients, and serial port communication parameters, setting and clearing buffer holding capacity, and data retrieval. IMACSS also controls FAME's supporting components (e.g. a motor or supplementary sensors for environmental variables such as air temperature, humidity, soil temperature, moisture content, broadband radiation). This software can flexibly control up to two spectrometers and a motor for multi-target measurements in three designs. It also allows a computer to be linked to FAME's datalogger either directly or remotely (via internet) to monitor and control FAME's operation, set parameters for measurements, and download the data.

GU, Lianhong↗

DOE OSTI2021

Developing an Eco-Cooperative Automated Control System (Eco-CAC)

The goal of the project was to develop a novel Eco-Cooperative Automated Control (Eco-CAC) system that integrates vehicle dynamics (VD) control with connected and automated vehicle (CAV) applications. In particular, the team developed a novel integrated control system that (1) routes vehicles in a fuel/energy-efficient manner for internal combustion engine vehicles (ICEVs), battery-only electric vehicles (BEVs), and hybrid electric vehicles (HEVs); (2) selects vehicle speeds based on anticipated traffic network evolution; (3) minimizes vehicle fuel/energy consumption near signalized intersections; and (4) intelligently modulates the longitudinal motion of vehicles within a cooperative platoon to minimize its fuel/energy consumption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Optimizing Facility Operations by Applying Machine Learning to the Army Reserve Enterprise Building Control System (Final Report)

Thousands of U.S. Department of Defense (DoD) buildings have building automation systems (BASs) and/or advanced meters. Although these systems have a wealth of data, performance optimization requires time and expertise to review and act on that information. Machine learning (ML) can provide automated and actionable insights to controls operators. This demonstration implemented proven ML methods on the Army Reserve Enterprise Building Control System. ML refers to algorithms that “learn” from data and improve their performance on a given task over time. In the buildings domain these tasks range from predicting future energy consumption, to identifying operational issues before faults occur, to optimizing control decisions. To learn, ML requires input data, which – for buildings – typically consists of instrument data such as energy consumption data and subsystem controls information such as set-point temperatures, and context data consisting of information such as the physical location of the building, the area of the building, and the weather. ML models use the relationships learned from the input data to make predictions with new, previously unseen, data. The team was able to investigate and successfully implement the following ML use cases: labeling consumption data as anomalous or non-anomalous; baseline whole-building load prediction (unknown fault status); fault detection (validation not possible); and site prioritization for energy-related projects. Due to the constraints of the project, interventions were not able to be implemented during the demonstration; therefore, assessments of operational cost savings and maintenance avoided could not be performed. The project has been presented at two leading national building conferences and two additional publications to peer-reviewed journals are currently in preparation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

First SELAP Algorithm Operational Experience of the New LLRF 3.0 RF Control System

The JLAB LLRF 3.0 system has been developed and is replacing the 30-year-old LLRF systems in the CEBAF accelerator. The LLRF system builds upon 25 years of design and operational RF control experience (digital and analog), and our recent collaboration in the design of the LCLSII LLRF system. The new system also incorporates a cavity control algorithm using a fully functional phase and amplitude locked Self Exciting Loop (SELAP). The first system (controlling 8 cavities) was installed and commissioned in August of 2021. Since then the new LLRF system has been operating with cavity gradients up to 20 MV/m, and electron beam currents up to 350 uA. This paper discusses the operational experience of the LLRF 3.0 SELAP algorithm along with other software and firmware tools like cavity and klystron characterization and quench detection.

Plawski, T. E.↗

DOE OSTI2020

Trigger-DAQ and Slow Controls Systems in the Mu2e Experiment

The muon campus program at Fermilab includes the Mu2e experiment that will search for a charged-lepton flavor violating processes where a negative muon converts into an electron in the field of an aluminum nucleus, improving by four orders of magnitude the search sensitivity reached so far. Mu2e's Trigger and Data Acquisition System (TDAQ) uses otsdaq as its solution. Developed at Fermilab, otsdaq uses the artdaq DAQ framework and art analysis framework, under the-hood, for event transfer, filtering, and processing. otsdaq is an online DAQ software suite with a focus on flexibility and scalability, while providing a multi-user, web-based, interface accessible through the Chrome or Firefox web browser. The detector Read Out Controller (ROC), from the tracker and calorimeter, stream out zero-suppressed data continuously to the Data Transfer Controller (DTC). Data is then read over the PCIe bus to a software filter algorithm that selects events which are finally combined with the data flux that comes froma Cosmic Ray Ve to System (CRV). A Detector Control System (DCS) for monitoring, controlling, alarming, and archiving has been developed using the Experimental Physics and Industrial Control System (EPICS) Open Source Platform. The DCS System has also been itegrated into otsdaq. The installation of the TDAQ and the DCS systems in the Mu2e building is planned for 2021-2022, and a prototype has been built at Fermilab's Feynman Computing Center. We report here on the developments and achievements of the integration of Mu2e's DCS system into the online otsdaq software.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2023

Implementation of AI/DEEP learning disruption predictor into a plasma control system

Abstract This paper reports on advances in the state‐of‐the‐art deep learning disruption prediction models based on the Fusion Recurrent Neural Network (FRNN) originally introduced in a 2019 NATURE publication [ https://doi.org/10.1038/s41586‐019‐1116‐4 ]. In particular, the predictor now features not only the “disruption score,” as an indicator of the probability of an imminent disruption, but also a “sensitivity score” in real time to indicate the underlying reasons for the imminent disruption. This adds valuable physics interpretability for the deep learning model and can provide helpful guidance for control actuators now implemented into a modern plasma control system (PCS). The advance is a significant step forward in moving from modern deep learning disruption prediction to real‐time control and brings novel AI‐enabled capabilities relevant for application to the future burning plasma ITER system. Our analyses use large amounts of data from JET and DIII‐D vetted in the earlier NATURE publication. In addition to “when” a shot is predicted to disrupt, this paper addresses reasons “why” by carrying out sensitivity studies. FRNN is accordingly extended to use more channels of information, including measured DIII‐D signals such as (i) the “n1rms” signal that is correlated with the n = 1 modes with finite frequency, including neoclassical tearing mode and sawtooth dynamics; (ii) the bolometer data indicative of plasma impurity control; and (iii) “q‐min”—the minimum value of the safety factor relevant to the key physics of kink modes. The additional channels and interpretability features expand the ability of the deep learning FRNN software to provide information about disruption subcategories as well as more precise and direct guidance for the actuators in a PCS.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2015

Air pollution control systems in WtE units: An overview

Highlights: • The paper describes in brief terms the development of gas cleaning in waste incineration. • The main technologies for pollutant removal are described including their basic mechanisms. • Their respective efficiencies and their application are discussed. • A cautious outlook regarding future developments is made. - Abstract: All WtE (waste-to-energy) plants, based on combustion or other thermal processes, need an efficient gas cleaning for compliance with legislative air emission standards. The development of gas cleaning technologies started along with environment protection regulations in the late 1960s. Modern APC (air pollution control) systems comprise multiple stages for the removal of fly ashes, inorganic and organic gases, heavy metals, and dioxins from the flue gas. The main technologies and devices used for abatement of the various pollutants are described and their basic principles, their peculiarities, and their application are discussed. Few systems for cleaning of synthesis gas from waste gasification plants are included. Examples of APC designs in full scale plants are shown and cautious prospects for the future development of APC systems are made.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Solar tracker control system and method

A pneumatic control unit configured to inflate a first and second set of bellows with fluid from a pneumatic fluid source via a pneumatic circuit, the first and second set of bellows associated with one or more pneumatic actuators. The pneumatic control unit determines a target configuration of the actuators based on a determined current position of the sun; determines a current configuration of the actuators; determines a difference between the determined current configuration and target configuration of the actuators; determines that the difference between current configuration and the target configuration of the actuators is outside of a tolerance range; and actuates the actuators toward the determined target configuration by at least one of inflating the first or second set of bellows with fluid from the pneumatic fluid source via the pneumatic circuit.

Betts, Kenneth H.↗

DOE OSTI2024

Using Generative AI to implement the discrepancy checker for a Nearly Autonomous Management and Control System for Advanced Reactors

Developments related to generative artificial intelligence (AI) have brought a major breakthrough in AI. These developments are rapidly accelerating developments in different science and engineering applications. Nearly Autonomous Management and Control (NAMAC) system provides recommendations to the operator for maintaining the safety and performance of the reactor. The discrepancy checker (DC) is an important component of the NAMAC) system, whose goal is to determine if the plant is moving towards the expected system state after the control actions are injected. In this work, we explore generative AI methods, particularly, a generative pretrained transformer (GPT) for implementing the DC function in NAMAC. The GPT-based DC aims to alert the operator in situations outside NAMAC’s scope and act as a chatbot the operator can use to retrieve relevant information. This study involves two versions of GPT developed by OpenAI: GPT-3.5 and GPT-4. These GPTs are trained on huge amounts of undisclosed general domain datasets. We explored two methods to adapt GPTs for DC implementation in NAMAC: fine-tuning and retrieval augmented generation. A small knowledge base (information file) that encompasses rules for DC implementation and some general information related to NAMAC has been created to support DC implementation using GPT. In this work, the GPT-based DC implementations have been tested for their reasoning abilities, comprehension, information retrieval, and extraction abilities. It should be noted that this paper only presents a preliminary study to test the feasibility of DC implementation using generative AI technology. Given the potential risks and severe consequences associated with nuclear reactor applications, combined with the black-box nature of AI, extensive offline and online testing and reliability analyses of GPT-based DCs are needed for further developing such capabilities.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗