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All sources NASA NTRS DOE OSTI

DOE OSTI2021

Real-Time Health Monitoring for Gas Turbine Components Using Online Learning and High-Dimensional Data (Final Report)

Capital-intensive turbomachinery, such as gas turbines and combined cycle plants, are constantly being monitored for performance anomalies, faults, and physical degradation. Although these power-generating assets are equipped with hundreds of sensors, existing monitoring tools can only handle moderate-sized data. As a result, only a handful of aggregate metrics are used to monitor machine health. At the same time, developing advanced tools suitable for large datasets have been restricted by the lack of appropriate data. The objective of this proposal was to demonstrate a Big Data analytics framework for fault detection and diagnosis in gas turbine applications. We develop a predictive analytics framework methodology guided by these experimental data, industrial data from our collaborators, and physics-based models with engineering domain knowledge. Our analytics framework consists of four key components: (1) a data curation process that addresses data storage, data quality assessments, and integrity checks, (2) a feature engineering component that utilizes statistical methods and transformation algorithms guided by physics-based models to extract high-fidelity fault features that can be leveraged for fault detection and classifying fault severities, (3) a Machine Learning-based fault detection and diagnostics algorithms for detecting operational and hardware faults in the combustion and the turbines section. We utilize two industry-class gas turbine component test rigs to generate first of its kind data for critical gas turbine faults with varying severity levels. Advanced gas turbine test facilities will be interrogated using state-of-the-art instrumentation techniques to build fault signatures and data trends for key combustor and turbine faults. Data generated from a combustor test rig (Georgia Tech) and a turbine test rig (Penn State) during both normal operation and with seeded faults serve as the basis for the Big Data sets. The test conditions in the two test facilities include common, critical events that occur in the operation. Utilizing the combustor test rig, we examine two common combustor faults: lean blowout and centerbody degradation. For the turbine section we develop analytic models for monitoring cooling faults in the gas turbine.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2023

Operational Focused Data Analytics for Optimizing Radiation Portal Monitor-Based Nuclear Smuggling Detection Systems at Global Ports of Entry

The National Nuclear Security Administration’s Office of Nuclear Smuggling Detection and Deterrence has deployed a fleet of radiation portal monitors (RPMs) across the world at global ports of entry including seaports, airports, and land border crossings. These RPMs are integrated into radiation detection systems (RDS) that also include fixed cameras, optical character recognition (OCR) systems, primary scanning systems (e.g., X-ray or gamma-ray), and secondary scanning systems (e.g., spectroscopic radiation portal monitors, portable radiation detection systems). The data from these sensing technologies is collected at the Central Alarm Station (CAS) where servers and computers reside to control and operate the system. Operators utilize the data collected by the CAS and declared cargo information to make decisions on how to respond to an alarm.This work explores the use of CAS-located data, looking at both the sensor data streams and operator inputs, to perform analysis which supports customs and border protection agencies to improve training capability and operational effectiveness. We focus on analyzing site level effectiveness and behavior by rolling up CAS-located data collected from individual occurrences. To-date, more than 15 sites (e.g., seaports, airports, border crossings) have been analyzed in this manner with the goal of understanding system operations to verify effectiveness and recommend potential improvements. This work first aims to provide background information on relevant CAS-located data sources and our current operational system analytics process including example results. After summarizing our current analytic techniques, we discuss how the future data analytics systems can provide key benefits to improving operational performance while minimizing the burden these detection systems place on operators.

Kuhn, Michael↗

DOE OSTI2019

DynamiteNSM

DynamiteNSM is a free Network Security Monitor (NSM), built on top of several leading, enterprise-grade technologies. The tool provides network and cybersecurity operators with holistic insights into their networks while giving them the ability to deep-dive into lower-level activities. The solution presents powerful dashboards, giving comprehensive view into performance and threat-based metrics. Dynamite-NSM can be easily deployed in different environments including high-speed data centers, small-to-large enterprises, IoT & industrial networks, and even at home. Dynamite-NSM handles massive volumes of network traffic through scalable ingestion and optimized network sensors. The solution includes two key components: the agent and the monitor. The agent analyzes and forwards network events, while the monitor processes incoming events and displays analytic information. The monitor component builds upon the OpenSearch stack and is coupled with network packet inspection by Zeek and Suricata. Dynamite-NSM is designed to be deployed very quickly with minimal configuration. Unlike many other tools, it can be installed and managed with a standalone command-line utility. The system is inherently passive without disruption to the network. There is no need to install agents on every computer, perform network scans, or directly interact with network assets.

Becker, Jamin↗

DOE OSTI2021

Data Fusion to Enhance Quality Control and Analysis with Instruments at the Marine and Coastal Research Laboratory

Deploying environmental monitoring instruments in the marine environment can be challenging, facing challenges around device survivability, biofouling and corrosion, and consistent data collection. This project explores the use of data fusion – the process of integrating multiple data sources to produce more consistent, accurate, and useful information – to build a consistent long-term monitoring system at the Marine and Coastal Research Laboratory (MCRL) in Sequim, Washington. Unused instruments that had been acquired from past projects were inventoried and deployments planned on the MCRL pier and floating dock. A total of 8 instruments were deployed including a tide gauge, hydrophone, acoustic Doppler current profiler (ADCP), photosynthetically active radiation (PAR) sensors, meteorological station, and three water quality sensors. Deployments were planned to be well-protected around the pier structure and a maintenance schedule was created for cleaning and recalibration. An automated data pipeline was created to aggregate data on edge computers that push data to Amazon Web Services (AWS) cloud storage every 15 minutes, performing automated quality control and data transformations using the Time Series Data Analytical Toolkit (TSDAT). Continued efforts are underway to maintain this system into the future, take a data-driven approach to maintenance scheduling, improve the reliability of the system, and share the data with a variety of end-users.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2019

Data Assessment and Assimilation for Atmospheric Radiation Measurement Data Using Dynamic Bayesian Networks

A data-driven machine learning approach to scientific sensor data assessment may automatically learn directly from the structural and temporal patterns in abundant observations. The project has developed data assessment and assimilation models to screen datasets using dynamic Bayesian network (DBN) and deep learning (DL) methods, which rely on correlations between variables, across time, and between spatial locations, to detect poor or invalid data with a high degree of confidence.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1973

A generalized technique for using cones and dihedral angles in attitude determination, revision 1

Analytic development is presented for a general least squares attitude determination subroutine applicable to spinning satellites. The method is founded on a geometric approach which is completely divorced from considerations relating to particular types and configurations of onboard attitude sensors. Any mix of sensor measurements which can be first transformed (outside the program) to cone or dihedral angle data can be processed. A cone angle is an angle between the spin axis and a known direction line in space; a dihedral angle is an angle between two planes formed by the spin axis and each of two known direction lines. Many different kinds of sensor data can be transformed to these angles, which in turn constitute the actual program inputs, so that the subroutine can be applied without change to a variety of satellite missions. Either a constant or dynamic spin axis model can be handled. The program is also capable of solving for fixed biases in the input angles, in addition to the spin axis attitude solution.

Werking, R. D.↗

DOE OSTI2018

Modeling of proton-induced radioactivation background in hard X-ray telescopes: Geant4-based simulation and its demonstration by Hitomi ’s measurement in a low Earth orbit

Hard X-ray astronomical observatories in orbit suffer from a significant amount of background due to radioactivation induced by cosmic-ray protons and/or geomagnetically trapped protons. Within the framework of a full Monte Carlo simulation, we present modeling of in-orbit instrumental background which is dominated by radioactivation. To reduce the computation time required by straightforward simulations of delayed emissions from activated isotopes, we insert a semi-analytical calculation that converts production probabilities of radioactive isotopes by interaction of the primary protons into decay rates at measurement time of all secondary isotopes. Therefore, our simulation method is separated into three steps: (1) simulation of isotope production, (2) semi-analytical conversion to decay rates, and (3) simulation of decays of the isotopes at measurement time. This method is verified by a simple setup that has a CdTe semiconductor detector, and shows a 100-fold improvement in efficiency over the straightforward simulation. To demonstrate its experimental performance, the simulation framework was tested against data measured with a CdTe sensor in the Hard X-ray Imager onboard the Hitomi X-ray Astronomy Satellite, which was put into a low Earth orbit with an altitude of 570 km and an inclination of 31°, and thus experienced a large amount of irradiation from geomagnetically trapped protons during its passages through the South Atlantic Anomaly. The simulation is able to treat full histories of the proton irradiation and multiple measurement windows. As a result, the simulation results agree very well with the measured data, showing that the measured background is well described by the combination of proton-induced radioactivation of the CdTe detector itself and thick Bi 4 Ge 3 O 12 scintillator shields, leakage of cosmic X-ray background and albedo gamma-ray radiation, and emissions from naturally contaminated isotopes in the detector system.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2022

Waveform processing using neural network algorithms on the front-end electronics

In a multi-channel radiation detector readout system, waveform sampling, digitization, and raw data transmission to the data acquisition system constitute a conventional processing chain. The deposited energy on the sensor is estimated by extracting peak amplitudes, area under pulse envelopes from the raw data, and starting times of signals or time of arrivals. However, such quantities can be estimated using machine learning algorithms on the front-end Application-Specific Integrated Circuits (ASICs), often termed as “edge computing”. Edge computation offers enormous benefits, especially when the analytical forms are not fully known or the registered waveform suffers from noise and imperfections of practical implementations. In this work, we aim to predict peak amplitude from a single waveform snippet whose rising and falling edges containing only 3 to 4 samples. We thoroughly studied two well-accepted neural network algorithms, Multi-Layer Perceptron (MLP) and Convolutional Neural Network (CNN) by varying their model sizes. Further, to better fit front-end electronics, neural network model reduction techniques, such as network pruning methods and variable-bit quantization approaches, were also studied. By combining pruning and quantization, our best performing model has the size of 1.5 KB, reduced from 16.6 KB of its full model counterpart. It can reach mean absolute error of 0.034 comparing to that of a naive baseline of 0.135. Such parameter-efficient and predictive neural network models established feasibility and practicality of their deployment on front-end ASICs.

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

Feed the fish: A review of aquaculture feeders and their strategic implementation

Automatic feeders are revolutionizing aquaculture by enabling precise and controlled feeding regimens that optimize growth, reduce feed waste, and enhance the overall efficiency of farming operations. Demand feeders provide some similar benefits but with feeding tailored to fish appetites and, in some cases, feed dispersal without electricity. This review explores the evolution, technological advancements, and applications of these feeders with a survey of recent research. It looks at common feeder designs and compares the pros and cons of five automatic feeder configurations in commercial use today. The article contrasts feeders and feed sizes for farmed species in different life stages and facilities, from hatcheries to ponds and offshore cages. It discusses the importance of species-tailored feeding strategies as well as impacts on fish behavior and health, nutrient delivery, and environmental sustainability. Incorporating sensors and on-site computing enables optimization in feeding algorithms that feeders then implement precisely and reliably. The review compiles results from multiple studies comparing growth rate, weight, and feed conversion ratio (FCR) outcomes from automatic feeders and demand feeders versus traditional hand-feeding regimens. The integration of feeders with real-time monitoring and data analytics is also discussed, highlighting future directions for research and adoption across the industry.

42 ENGINEERING↗

NASA NTRS1983

Satellites map the oceans

Satellite remote sensing systems, both operational and planned, for monitoring the ocean winds, temperatures, chlorophyll concentrations, ice flows, and the sea surface and ocean floor topographies are described. Seasat demonstrated the effectiveness of scatterometer measurements for measuring wind velocities and directions, and a new scatterometer may be launched on the U.S. Navy NROSS spacecraft in 1988. The NOAA-7 and -8 satellites carry IR sensors to monitor ocean temperatures, and can thus forewarn of the onset of El Nino. Ocean currents are traced with radar altimeters such as the one planned for the Topex satellite as a follow-on to instrumentation tested during the three-month lifetime of the Seasat satellite. Further analytical development is required, however, to improve the data analyses of the altimeter and scatterometer readings, and to account for errors introduced by the observed features and the interposed atmospheric phenomena.

Hibbs, A. R.↗

NASA NTRS1993

A model-based approach for detection of objects in low resolution passive millimeter wave images

A model-based vision system to assist the pilots in landing maneuvers under restricted visibility conditions is described. The system was designed to analyze image sequences obtained from a Passive Millimeter Wave (PMMW) imaging system mounted on the aircraft to delineate runways/taxiways, buildings, and other objects on or near runways. PMMW sensors have good response in a foggy atmosphere, but their spatial resolution is very low. However, additional data such as airport model and approximate position and orientation of aircraft are available. These data are exploited to guide our model-based system to locate objects in the low resolution image and generate warning signals to alert the pilots. Also analytical expressions were derived from the accuracy of the camera position estimate obtained by detecting the position of known objects in the image.

Kasturi, Rangachar↗

DOE OSTI2019

An Automated, Disruption-Tolerant Device Authentication and Key Management Framework for Critical Systems

Key management is critical to secure operation. Distributed control systems, such as Supervisory Control and Data Acquisition (SCADA) systems, have unique operational requirements that make conventional key management solutions less effective and burdensome. In this paper a novel Kerberos based framework for automated, disruption-tolerant key management for control system environments is presented. Experimental tests and their results are presented to quantify expected performance overhead of this approach. In addition, Zeek sensor analytics are presented to monitor the health and security of the key management framework operation.

Edgar, Thomas W.↗

DOE OSTI2020

An Automated Disruption-Tolerant Key Management Framework for Critical Systems

Key management is critical to secure operation. Distributed control systems, such as Supervisory Control and Data Acquisition (SCADA) systems, have unique operational requirements that make conventional key management solutions less effective and burdensome. This paper presents a novel Kerberos-based framework for automated, disruption-tolerant key management for control system environments. Here, experimental tests and their results are presented to quantify the expected performance overhead of this approach. Additionally, Zeek sensor analytics are presented to aid in monitoring the health and security of the key management framework operation.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗

DOE OSTI2025

Expediting field-effect transistor chemical sensor design with neuromorphic spiking graph neural networks

Improving the sensitive and selective detection of analytes in a variety of applications requires accelerating the rational design of field-effect transistor (FET) chemical sensors. Achieving high-performance detection relies on identifying optimal probe materials that can effectively interact with target analytes, a process traditionally driven by chemical intuition and time-consuming trial-and-error methods. To address the difficulties in probe screening for FET sensor development, this work presents a methodology that combines neuromorphic machine learning (ML) architectures, specifically a hybrid spiking graph neural network (SGNN), with an enriched dataset of physicochemical properties through semi-automated data extraction using large language models. Achieving a classification accuracy of 0.89 in predicting sensor sensitivity categories, the SGNN model outperformed traditional ML techniques by leveraging its ability to capture both global physicochemical properties and sparse topological features through a hybrid modeling framework. Next-generation sensor design was informed by the actionable insights into the connections between material properties and sensing performance offered by the SGNN framework. Through virtual screening for the detection of per- and polyfluoroalkyl substances (PFAS) as a use case, the effectiveness of the SGNN model was further validated. Density functional theory simulations confirmed graphene as a promising active material for PFAS detection as suggested by the SGNN framework. By bridging gaps in predictive modeling and data availability, this integrated approach provides a strong foundation for accelerating advancements in FET sensor design and innovation.

Ferreira, Rodrigo Pires [Univ. of Chicago, IL (Uni↗

DOE OSTI2020

Online Parameter Estimation Methods for Adaptive Cruise Control Systems

Modeling Adaptive Cruise Control (ACC) vehicles enables the understanding of the impact of these vehicles on traffic flow. In this work, two online methods are used to provide real time system identification of ACC enabled vehicles. The first technique is a recursive least squares (RLS) approach, while the second method solves a nonlinear joint state and parameter estimation problem via particle filtering (PF). We provide a parameter identifiability analysis for both methods to analytically show that the model parameters are not identifiable using equilibrium driving. The accuracy and computational runtime of the online methods are compared to a commonly used offline simulation-based optimization (i.e., batch optimization) approach. The methods are tested on synthetic data as well as on empirical data collected directly from a 2019 model year ACC vehicle using data from sensors that are part of the stock ACC system. The online methods are scalable and provide comparable accuracy to the batch method. RLS runs in real time and is two orders of magnitude faster than the batch method for modest sized (e.g., 15 min) datasets. The particle filter also runs in real- time, and is also suitable in streaming applications in which the datasets can grow arbitrarily large.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS2023

Characterization of Errors in Satellite-Based HCHO/NO 2 Tropospheric Column Ratios With Respect to Chemistry, Column-to-PBL Translation, Spatial Representation, and Retrieval Uncertainties

The availability of formaldehyde (HCHO) (a proxy for volatile organic compound reactivity) and nitrogen dioxide (NO 2 ) (a proxy for nitrogen oxides) tropospheric columns from ultraviolet–visible (UV–Vis) satellites has motivated many to use their ratios to gain some insights into the near-surface ozone sensitivity. Strong emphasis has been placed on the challenges that come with transforming what is being observed in the tropospheric column to what is actually in the planetary boundary layer (PBL) and near the surface; however, little attention has been paid to other sources of error such as chemistry, spatial representation, and retrieval uncertainties. Here we leverage a wide spectrum of tools and data to quantify those errors carefully. Concerning the chemistry error, a well-characterized box model constrained by more than 500 h of aircraft data from NASA's air quality campaigns is used to simulate the ratio of the chemical loss of HO 2 + RO 2 (LRO x ) to the chemical loss of NO x (LNO x ). Subsequently, we challenge the predictive power of HCHO/NO 2 ratios (FNRs), which are commonly applied in current research, in detecting the underlying ozone regimes by comparing them to LRO x /LNO x . FNRs show a strongly linear (R 2 =0.94) relationship with LRO x /LNO x , but only on the logarithmic scale. Following the baseline (i.e., ln(LRO x /LNO x ) = −1.0 ± 0.2) with the model and mechanism (CB06, r2) used for segregating NO x -sensitive from VOC-sensitive regimes, we observe a broad range of FNR thresholds ranging from 1 to 4. The transitioning ratios strictly follow a Gaussian distribution with a mean and standard deviation of 1.8 and 0.4, respectively. This implies that the FNR has an inherent 20 % standard error (1σ) resulting from not accurately describing the RO x –HO x cycle. We calculate high ozone production rates (PO 3 ) dominated by large HCHO × NO 2 concentration levels, a new proxy for the abundance of ozone precursors. The relationship between PO 3 and HCHO × NO 2 becomes more pronounced when moving towards NO x -sensitive regions due to nonlinear chemistry; our results indicate that there is fruitful information in the HCHO × NO 2 metric that has not been utilized in ozone studies. The vast amount of vertical information on HCHO and NO 2 concentrations from the air quality campaigns enables us to parameterize the vertical shapes of FNRs using a second-order rational function permitting an analytical solution for an altitude adjustment factor to partition the tropospheric columns into the PBL region. We propose a mathematical solution to the spatial representation error based on modeling isotropic semivariograms. Based on summertime-averaged data, the Ozone Monitoring Instrument (OMI) loses 12 % of its spatial information at its native resolution with respect to a high-resolution sensor like the TROPOspheric Monitoring Instrument (TROPOMI) (> 5.5 × 3.5 km 2 ). A pixel with a grid size of 216 km 2 fails at capturing ∼ 65 % of the spatial information in FNRs at a 50 km length scale comparable to the size of a large urban center (e.g., Los Angeles). We ultimately leverage a large suite of in situ and ground-based remote sensing measurements to draw the error distributions of daily TROPOMI and OMI tropospheric NO 2 and HCHO columns. At a 68 % confidence interval (1σ), errors pertaining to daily TROPOMI observations, either HCHO or tropospheric NO 2 columns, should be above 1.2–1.5 × 10 16 molec. cm −2 to attain a 20 %–30 % standard error in the ratio. This level of error is almost non-achievable with the OMI given its large error in HCHO. The satellite column retrieval error is the largest contributor to the total error (40 %–90 %) in the FNRs. Due to a stronger signal in cities, the total relative error (< 50 %) tends to be mild, whereas areas with low vegetation and anthropogenic sources (e.g., the Rocky Mountains) are markedly uncertain (> 100 %). Our study suggests that continuing development in the retrieval algorithm and sensor design and calibration is essential to be able to advance the application of FNRs beyond a qualitative metric.

Amir H. Souri↗

DOE OSTI2026

Enhanced Preparation for Intelligent Cybermanufacturing Systems (EPICS)

Opportunities exist for realizing transformative advances in productivity and reductions in energy footprint through ubiquitous sensing in manufacturing environments. Enhanced Preparation for Intelligent Cybermanufacturing Systems (EPICS) is a 21-month (4 academic semesters, plus one summer) experience for graduate students that focuses on scaling the knowledge, understanding and leadership skills in the cyber manufacturing area. Masters students (8/year, 32 total) complete 2-year projects on industrially-driven project topics, rotating to internships in summer semester to work on scoping and implementation at project partners. Students complete academic training in embedded systems, process modeling, data science, and cloud-based systems design. Their projects are targeted toward sensor retrofit, process monitoring, root cause analysis, and sensor fusion.

Advanced Manufacturing↗

DOE OSTI2020

A Hybrid AI/ML and Computational Mechanics Based Approach for Time-Series State and Fatigue Life Estimation of Nuclear Reactor Components

Environmental fatigue modeling is a complex problem due to multiple failure modes and their intermixing. The failure modes are function of various underlying causes in addition to the corrosive effect of reactor coolant environment. Some of the major causes are time-dependence of material associated with cyclic loading, load sequence effect associated with random/variable amplitude loading, effect of strain amplitude and rates, effect of varying temperature (along both temporal and spatial directions) and the effect of mean strain and stress. The nonlinear intermixing of failure modes associated with above mentioned causing parameters makes the environmental fatigue modeling is a challenging task. Because of this challenge, fatigue is traditionally being modeled based on experimental data. However, test based empirical approach often requires hundreds of fatigue tests to model the above-mentioned intermixing failure causes even for a single material system. The problem is further exaggerated for reactor component made from multi-material systems such as made from both carbon and stainless-steel base metals and their similar and dissimilar metal welds. With the difficulty of conducting hundreds of fatigue tests to capture the above-mentioned intermixing failure causes, fatigue modeling approaches often depends on empirical models based on limited available test data such as available through ASME code and NUREG 6909. However, these limited test-data-based models may not be enough to accurately predict the life of reactor components. Accurate prediction of life of reactor component would become a necessity, particularly when the license of the reactors to be extended for long-term-operation (LTO) that is for well beyond its original design life of 40 years. The requirement of extending the license of reactor under LTO requires hundreds of fatigue tests to be conducted to understand the mechanism associated with the above-mentioned interdependent failure causes. However, conducting large number of fatigue tests is not a feasibility due to the cost involved. To address this issues Argonne National Laboratory (ANL) with the sponsorship of DOE Light Water Reactor Sustainability (LWRS) program trying to develop a hybrid predictive modeling approach. This is based on limited experiment-data, Artificial-intelligence (AI) – Machine-Learning (ML) - Deep-Learning (DL) based techniques and Multiphysics-computational-mechanics based modeling tools. The hybrid approach not-only can improve the accuracy of the existing stress analysis and fatigue modeling approach but also can reduce the over-dependency on test-based approach. Towards this goal following are some of the major contributions based on ANL’s FY-20 environmental fatigue modeling activities: 1) A cyclic plasticity material model database for 82/182 dissimilar metal weld, which can be readily shared with US nuclear industry and regulatory agency on request. 2) A well validated analytical modeling methodology to perform cycle-by-cycle stress prediction under both constant amplitude fatigue loading and variable amplitude fatigue loading (with load-sequence effect). 3) An AI/ML/DL based methodology to predict unmeasurable cyclic strain based on other available sensor signals. This type of approach can be used for estimating strain in real reactor components from other sensor readings. 4) An AI/ML based approach to improve the US capability on environmental fatigue testing. This is by improving ANL’s existing environmental fatigue testing capacity to conduct ASME required strain-controlled tests (by controlling strain amplitudes and its rate), while not measuring the strain (due to the difficulty of placing an extensometer in a narrow autoclave in a PWR-water-test system). 5) A simulation and experiment based probabilistic modeling methodology for time-series fatigue state and life estimation of reactor metal such as dissimilar metal weld.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗