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Contributions of GRACE to Climate Monitoring

The NASA/German Gravity Recovery and Climate Experiment (GRACE) was launched in March 2002. Rather than looking downward, GRACE continuously monitors the locations of and precise distance between twin satellites which orbit in tandem about 200 km apart. Variations in mass near Earth's surface cause heterogeneities in its gravity field, which in turn affect the orbits of satellites. Thus scientists can use GRACE data to map Earth's gravity field with enough accuracy to discern month to month changes caused by ocean circulation and redistribution of water stored on and in the land. Other gravitational influences, such as atmospheric circulation, post-glacial rebound, and solid earth movements are either independently determined and removed or are negligible on a monthly to sub-decadal timescale. Despite its coarse spatial (>150,000 sq km at mid-latitudes) and temporal (approx monthly) resolutions, GRACE has enabled significant advancements in the oceanic, hydrologic, and cryospheric science, and has great potential for climate monitoring, because it is the only global observing system able to measure ocean bottom pressures, total terrestrial water storage, and ice mass changes. The best known GRACE results are estimates of Greenland and Antarctic ice sheet loss rates. Previously, scientists had estimated ice mass losses using ground and satellite based altimetry and surface mass balance estimates based on snowfall accumulation and glacier discharge. While such measurements are still very useful for their spatial detail, they are imperfectly correlated with large-scale ice mass changes, due to snow and ice compaction and incomplete spatial coverage. GRACE enables scientists to generate monthly time series of Greenland and Antarctic ice mass, which have confirmed the shrinking of the polar ice sheets, one of the most obvious and indisputable manifestations of climate change. Further, GRACE has located and quantified hot spots of ice loss in southeastern Greenland and western Antarctica. For 2002 to present, the rate of ice mass loss has been 200 to 300 GT/yr in Greenland and 70 to 210 GT/yr in Antarctica, and some scientists are suggesting that the rates are accelerating. Similarly, GRACE has been used to monitor mass changes in alpine glaciers. Tamisiea et al. first characterized glacier melt along the southern coast of Alaska, more recently estimated to be occurring at a rate of 84 GT/yr. Chen et al. estimated that Patagonian glaciers are melting at a rate of 28 GT/yr, and estimated that the high mountains of central Asia lose ice at a rate of 47 GT/yr. Tapley et al. and Wahr et al. presented the first GRACE based estimates of changes in column-integrated terrestrial water storage (TWS; the sum of ground-water, soil moisture, surface waters, snow, ice, and water stored in vegetation) at continental scales. Since then, dozens of studies have shown that GRACE based estimates of regional to continental scale TWS variations agree with independent information, and some innovative uses of GRACE data have been developed. Rodell et al. (2004) and Swenson and Wahr (2006) demonstrated that by combining GRACE derived terrestrial water storage changes with observations of precipitation and runoff in a river basin scale water budget, it was possible to produce new estimates of evapotranspiration and atmospheric moisture convergence, essential climate variables that are difficult to estimate accurately. Similarly, GRACE has been used to constrain estimates of global river discharge and the contribution of changes in TWS to sea level rise. Crowley et al. observed a negative correlation between interannual TWS anomalies in the Amazon and the Congo River basin. Yeh et al. and Rodell et al. estimated regionally averaged groundwater storage variations based on GRACE and auxiliary observations. Rodell et al. and Tiwari et al. applied that method to quantify massive groundwater depletion in northern India caused by over reliance on aquifers for irration, and Famiglietti et al. found a similar situation in California's Central Valley. Zaitchik et al. and Lo et al. described approaches to use GRACE to constrain hydrological models, enabling integration of GRACE data with other observations and achieving much higher spatial and temporal resolutions than GRACE alone. Such approaches are now supporting applications including drought and water resources monitoring. Oceanography has likewise benefitted from the independent nature of GRACE observations. One application is measurement of the mass component of sea level rise, which complements radar altimetry and in situ measurements. GRACE also measures ocean bottom pressures (OBP), which help to refine understanding and modeling of ocean circulation and the ocean's fresh water budget, among other things. For example, Hayakawa et al. showed that GRACE observes OBP patterns absent from the background models of oceanic variability. Morison et al. used GRACE to describe important decadal scale shifts in circulation and an ongoing trend of freshening of the western Arctic, important indicators of climate variability. The research of Song and Zlotnicki and Chambers and Willis on GRACE-derived ocean bottom pressures in the sub-polar gyre led to the discovery of an ENSO teleconnection and a long-term change in OBP in the North Pacific sub-polar gyre that was not predicted by an ocean model. Further, Chambers and Willis were able to identify an internal redistribution of mass between Atlantic and Pacific Oceans lasting at least six years, which was not predicted by ocean models and was the first direct evidence of sustained mass transport from one ocean basin to another on periods longer than a year. Boening et al. observed a record increase in OBP over part of the southeastern Pacific in late 2009 and early 2010, primarily caused by wind stress curl associated with a strong and persistent anticyclone and likely related to the concurrent Central Pacific El Nino. GRACE has far surpassed its 5-year design lifetime, but it will likely succumb to the aging of batteries and instrument systems sometime in the next few years. NASA has begun initial development of a follow-on to GRACE with very similar design, which could launch as soon as 2016 and would provide continuity in the data record while improving resolution slightly. Higher resolution time variable gravity missions are also on the drawing board .

Rodell, Matthew↗

Transport effects due to particle erosion mechanisms

Various processes can erode the surfaces of planetary ring particles. Recent estimates for Saturn's rings suggest that a centimeter-thick surface layer could be eroded from an isolated ring particle in less than 1000 yr by meteoroid impacts alone. The atoms, molecules, and chips ejected from ring particles by erosion will arc across the rings along elliptical orbits. For moderate ring optical depths, ejecta will be absorbed or inelastically scattered upon reintersecting the ring plane. Continuous exchange of ejecta between different ring regions can lead to net radial transport of mass and angular momentum, to changes in particle sizes, and to the buildup of chip regoliths several centimeters deep on the surfaces of ring particles. Because most of the erosional ejecta are not lost but merely exchanged over short distances, the net erosion rate of the surfaces of these ring particles will be much less than that estimated for an isolated particle. Numerical solutions for time-dependent ballistic transport under various assumptions suggest pile-up and spillover effects especially near regions of preexisting high optical depth contrast, such as the inner edges of A and B rings. Global redistribution could be significant over billions of years. Other features in planetary ring systems may be influenced by ballistic transport.

Durisen, R. H.↗

Noninvasive Sensor for Measuring Muscle Metabolism During Exercise

The measurement of oxygen uptake (VO2) and lactate threshold (LT) are utilized to assess changes in aerobic capacity and the efficacy of exercise countermeasures in astronauts. During extravehicular activity (EVA), real-time knowledge of VO2 and relative work intensity can be used to monitor crew activity levels and organize tasks to reduce the cumulative effects of fatigue. Currently VO2 and LT are determined with complicated measurement techniques that require sampling of expired ventilatory gases, which may not be accurate in enclosed, oxygen-rich environments such as the EVA suit. The UMMS team has developed a novel near infrared spectroscopic (NIRS) system which noninvasively, simultaneously and continuously measures muscle oxygen tension, oxygen saturation, pH (pHm), and hematocrit from a small sensor placed on the leg. This system is unique in that it allows accurate, absolute measurement of these parameters in the thigh muscle by correcting spectra for the interference from skin pigment and fat. These parameters can be used to estimate VO2 and LT. A preliminary evaluation of the system s capabilities was performed in the NASA JSC Exercise Physiology Lab.

Soller, B. R.↗

Coronas-F Orbit Monitoring and Re-Entry Prediction

Russian scientific satellite CORONAS-F was launched on July, 31, 2001. The object was inserted in near-circular orbit with the inclination 82.5deg and a mean altitude approx. 520 km. Due to the upper atmosphere drag CORONAS-F was permanently descended and as a result on December, 6, 2005 it has finished the earth-orbital flight, having lifetime in space approx. 4.5 years. The satellite structural features and its flight attitude control led to the significant variations of its ballistic coefficient during the flight. It was a cause of some specific difficulties in the fulfillment of the ballistic and navigation support of this space vehicle flight. Besides the main mission objective CORONAS-F also has been selected by the Inter-Agency Space Debris Coordination Committee (IADC) as a target object for the next regular international re-entry test campaign on a program of surveillance and re-entry prediction for the hazard space objects within their de-orbiting phases. Spacecraft (S/C) CORONAS-F kept its working state right up to the end of the flight - down to the atmosphere entry. This fact enabled to realization of the additional research experiments, concerning with an estimation of the atmospheric density within the low earth orbits (LEO) of the artificial satellites, and made possible to continue track the S/C during final phase of its flight by means of Russian regular command & tracking system, used for it control. Thus there appeared a unique possibility of using for tracking S/C at its de-orbiting phase not only passive radar facilities, belonging to the space surveillance systems and traditionally used for support of the IADC re-entry test campaigns, but also more precise active trajectory radio-tracking facilities from the ground control complex (GCC) applied for this object. Under the corresponding decision of the Russian side such capability of additional high-precise tracking control of the CORONAS-F flight in this period of time has been implemented. The organizing of the CORONAS-F ballistic and navigational support (BNS) and solving its main tasks (such as S/C orbit determination (OD) and its motion prediction and connected with them) both for regular mission stage and for additional flight program were realized by the group of specialists from the Mission Control Center (MCC). MCC was also assigned as a principal organization from the Russian side for participation in the 7th IADC re-entry test campaign on CORONAS-F. The CORONAS-F flight features and space environments circumstances during its flight as well as a methodology and technology of spacecraft ballistic and navigational support are given below. The BNS results for different phases of S/C flight, including the results of its re-entry predictions, obtained during the realization of the 7th IADC test campaign are submitted. The accuracy of space vehicle re-entry prediction and its dependence on various factors are analyzed in more details.

Ivanov, N. M.↗

Estimating Water Ice Abundance from Short-Wave Infrared Spectra of Drill Cuttings at Cryogenic Temperatures

NASA's Resource Prospector (RP) mission intends to visit a lunar polar region to characterize the volatile distribution. Part of the RP payload, the Near-infrared Volatile Spectrometer System (NIRVSS) is a spectrometer operating from 1600-3400 nm that provides sensitivity to water ice, and other volatiles. For multiple years, the NIRVSS system has been incorporated into on-going RP payload testing in a cryogenic vacuum facility at Glenn Research Center. Soil tubes of lunar simulants, prepared with known amounts of water, are placed in the vacuum chamber and cooled to cryogenic temperatures (soil temperatures of 110-170 K) and placed under low vacuum (a few x 10(exp -6) Torr). During these tests NIRVSS continuously measures spectra of soil cuttings emplaced onto the surface by a drill. Real time processing of NIRVSS spectra produces two spectral parameters associated with water ice absorption features near 2000 and 3000 nm that can be used to inform decision making activities such as delivery of the soil to a sealable container. Post-test collection and analyses of the soils permit characterization the water content as a function of depth. These water content profiles exhibit the characteristics of a vacuum desiccation zone to depths of about 40 cm. Subsequent to completion of the tests, NIRVSS spectra are processed to produce two spectral parameters associated with water ice absorption features near 2000 and 3000 nm. These features can be evaluated as a function of time, and correlated with drill depth, and other measurements, throughout the drilling activities. Until now no effort was attempted to quantitatively relate these parameters to water abundance. This is the focus of our efforts to be presented.

NASA's Resource Prospector (RP)↗

Weighted Composition Operators for Learning Nonlinear Dynamics

Operator theoretic methods in dynamical system have been dominated by the use of Koopman operators and their continuous time counterparts, such as Koopman Generators and Liouville Operators. The advantage gained from their use primarily stems from the ability to extract subspaces and eigenfunctions within a space of observables that are invariant with respect to the Koopman operator over that space. When this occurs, a dynamic mode decomposition of the systems state provides a linear model for the dynamical system. Not all Koopman operators have eigenfunctions that may be exploited in this manner. However, the framework can still be leveraged for approximations using other operators. In this setting, we present a different operator for the study of dynamical systems, the weighted composition operator. These operators are compact for a wide range of dynamics and spaces, and through their interactions with occupation kernels and vector valued kernels, they admit an estimation of the underlying dynamics. Here, this manuscript presents a new algorithm for the data driven study of dynamical systems from data, and also provides two numerical experiments where convergence is achieved as a proof of concept.

97 MATHEMATICS AND COMPUTING↗

What Can We Learn from One Billion Ground System Log Messages?

Shortage of log-based data in a ground system they have traditionally been the under achievers in a satellite ground system. This is due to several factors: Once log messages scroll out of view on the TTC event console window they are soon forgotten. Application and system log files are scattered across directories within a system, across a multitude of servers, and across one or more databases making access cumbersome. Typical tools to perform log file content searching are generally crude and typically only employed as part of trouble-shooting exercises.As we move towards satellite constellations and fleets and add even more status information, the number of messages keeps growing. One mission now estimates that they could generate 3,000,000 messages per day 1 billion per year - for the life of their mission. What to do with those 1 billion messages? That is the challenge. With the recent technological advances in the management of large data sets, text-based processing, and data analytics, there are now capabilities that we can provide to the ground system engineers and satellite operators to address what we postulate are missed opportunities. Advanced real-time log analysis can allow us to be less reactionary in favor of being more proactive. Analytics goals include the ability to: Identify root cause of unexpected events, failures or error conditions enabled by correlating disparate data. Detect security breaches attempts before they are successful. Help admins ensure IT resources continue running optimally. Identify trends and patterns that may indicate impending failures or error conditions for valuable assets before they happen. Compare satellites in a fleet or constellation in terms of number of alarms, number of command sent to them, etc.. Answer questions like "Are the operations support needs increasing over the past year?" or "Have we seen this combination of alarm conditions before?" But really, once the tools are readily available the users will start realizing what can be done with their new powers. In this presentation we will show the results of analyzing millions of actual mission operations log messages, how the results can be displayed to the user, and how new products now available as open source can be applied to the challenges of large scale time-tagged text-based mission operations messages. Flight operations team members believe that this is a powerful new option for how they assess overall system and space asset health. Technical descriptions of the design, tools, and storage will be provided. One billion messages? Bring'em on!

Orsborne, Sharon↗

Smart Power Supply for Battery-Powered Systems

A power supply for battery-powered systems has been designed with an embedded controller that is capable of monitoring and maintaining batteries, charging hardware, while maintaining output power. The power supply is primarily designed for rovers and other remote science and engineering vehicles, but it can be used in any battery alone, or battery and charging source applications. The supply can function autonomously, or can be connected to a host processor through a serial communications link. It can be programmed a priori or on the fly to return current and voltage readings to a host. It has two output power busses: a constant 24-V direct current nominal bus, and a programmable bus for output from approximately 24 up to approximately 50 V. The programmable bus voltage level, and its output power limit, can be changed on the fly as well. The power supply also offers options to reduce the programmable bus to 24 V when the set power limit is reached, limiting output power in the case of a system fault detected in the system. The smart power supply is based on an embedded 8051-type single-chip microcontroller. This choice was made in that a credible progression to flight (radiation hard, high reliability) can be assumed as many 8051 processors or gate arrays capable of accepting 8051-type core presently exist and will continue to do so for some time. To solve the problem of centralized control, this innovation moves an embedded microcontroller to the power supply and assigns it the task of overseeing the operation and charging of the power supply assets. This embedded processor is connected to the application central processor via a serial data link such that the central processor can request updates of various parameters within the supply, such as battery current, bus voltage, remaining power in battery estimations, etc. This supply has a direct connection to the battery bus for common (quiescent) power application. Because components from multiple vendors may have differing power needs, this supply also has a secondary power bus, which can be programmed a priori or on-the-fly to boost the primary battery voltage level from 24 to 50 V to accommodate various loads as they are brought on line. Through voltage and current monitoring, the device can also shield the charging source from overloads, keep it within safe operating modes, and can meter available power to the application and maintain safe operations.

Krasowski, Michael J.↗

Evaluating the Socioeconomic Impacts of Rapid Assembly and Deployment of Geospatial Data in Wildfire Emergency Response Planning: A Case Study Using the NASA RECOVER Decision Support System (DSS)

Today’s extended fire seasons and large fire footprints have prompted state and federal land management agencies to devote increasingly larger portions of their budget to wildfire management. As fire costs continue to rise, timely and comprehensive fire information becomes increasingly critical to response and rehabilitation efforts. The NASA Rehabilitation Capability Convergence for Ecosystem Recovery (RECOVER) post-fire decision support system is a server-based application designed to rapidly provide land managers with the information needed to develop a comprehensive rehabilitation plan. This study tested the efficacy of RECOVER through structured interviews with land managers (n=15) who used RECOVER and were responsible for post-fire rehabilitation efforts on over 645 000 ha of fire-affected lands. Although the benefit of better-informed decisions is difficult to quantify, the results of this study illustrate RECOVER’s decision support capabilities provided information to land managers that either validated or altered their decisions on post-fire treatments estimated at over $1.2 million (USD) and saved nearly 800 hours of staff time by streamlining data collection as well as communication with local stakeholders and partnering agencies.

William Toombs↗

Pilot Field Test: Performance of a Sit-to-Stand Test After Long-Duration Space Flight

BACKGROUND: Astronauts returning from the International Space Station are met by a team of recovery personnel typically providing physical assistance and medical support immediately upon landing. That is because long-duration spaceflight impacts astronauts' functional abilities. Future expeditions to planets or asteroids beyond the low Earth orbit, however, may require crewmembers to egress the vehicle and perform other types of physical tasks unassisted. It is therefore important to characterize the extent and longevity of functional deficits experienced by astronauts in order to design safe exploration class missions. Pilot Field Test (PFT) experiment conducted with participation of ISS crewmembers traveling on Soyuz expeditions 34S - 41S comprised several tasks designed to study the recovery of sensorimotor abilities of astronauts during the first 24 hours after landing and beyond. METHODS: The first test in the PFT battery sequence, and also the least demanding one from the sensorimotor perspective, was a Sit-to-Stand test. Test subjects were seated in the chair and had to stand up on command and remain standing for ten seconds. The subjects were instructed to stand up unassisted as quickly as they were able to, while maintaining postural control. Synchronized wireless inertial sensors mounted on the head, chest, lower back, wrists, and ankles were used to continuously log body kinematics. Crewmembers' blood pressure and heart rate were monitored and recorded with the Portapres and Polar systems. Each session was recorded with a digital video camera. During data collections occurring within the 24-hour postflight period, crewmembers were also asked to (1) evaluate their perceived motion sickness symptoms on a 20-point scale before and after completion of the test and (2) estimate how heavy they felt compared to their normal (preflight) body weight. Consent to participate in PFT was obtained from 18 crewmembers (11 US Orbital Segment [USOS] astronauts and 7 Russian cosmonauts). For 10 subjects, the first set of data was collected in the medical tent in Soyuz landing zone (1-2 hours after landing); the other 8 subjects were tested at the Kazakhstan deployment airport (4-5 hours after landing). 8 of the 11 astronauts were tested twice more within the first 24 hours postflight, at a refueling stop on the way to Houston (approximately 13 hours after landing) and at the Johnson Space Center (approximately 24 hours after landing). Later postflight data were collected in the first two weeks on some crewmembers. Finally, 6 astronauts were tested 60+ days after landing to establish a delayed baseline. RESULTS/DISCUSSION: Two of the 18 PFT participants felt too ill to attempt any tests in Kazakhstan (at either the landing zone or deployment airport). The remaining test subjects completed the Sit-to-Stand test and their reported motion sickness scores were unaffected by this task. The task completion times and body kinematics data analysis are currently underway. Preliminary analysis of astronaut data shows a steep improvement in the time to complete the task on the second data take, and in some cases, the trend continues through day six postflight. Head and trunk pitch angles and pitch rates were also examined and increases in all measures are evident throughout the observed recovery period (60+ days postflight). Interesting patterns of head and trunk pitch coordination have also emerged. One of the data analysis objectives is comparison of initial postflight performance and recovery of experienced crewmembers and first-time fliers. Another one - possible differences in performance between USOS and Russian crewmembers.

Kofman, I. S.↗

Real-Time Temperature Field State Observer and Digital Replica to Support Cyber-Physical Testing

Cyber-physical testing is a class of experimental methods in which a system is partitioned into physical and numerical components to study its overall behavior. Transfer systems are typically needed to capture relevant interactions by enforcing appropriate interface conditions between the physical and numerical portions. While cyber-physical testing is often performed using lumped-parameter systems, thermomechanical cyber-physical testing requires the use of thermal actuators as transfer systems to apply a thermal condition over a spatially distributed region or surface. Thus, the interactions between the numerical and physical components are of a distributed nature, i.e., a field rather than point values. In this paper, we develop and experimentally validate a state observer for temperature fields to enable thermomechanical cyber-physical testing. The state observer provides continuous estimates of temperature over a surface of the thermal actuator using only temperature measurements at discrete locations. The estimated temperature field is then leveraged to account for localized mechanical defects in the interface condition. The method consists of building a digital replica of one portion of the control plant. By imposing defects in the digital replica it is used to generate and output the response of a thermal load pattern that represents that of a physical system with mechanical defects.

Manuel Salmeron↗

Closed Loop Geothermal Working Group: GeoCLUSTER App, Subsurface Simulation Results, and Publications

To better understand the heat production, electricity generation performance, and economic viability of closed-loop geothermal systems in hot-dry rock, the Closed-Loop Geothermal Working Group -- a consortium of several national labs and academic institutions has tabulated time-dependent numerical solutions and levelized cost results of two popular closed-loop heat exchanger designs (u-tube and co-axial). The heat exchanger designs were evaluated for two working fluids (water and supercritical CO2) while varying seven continuous independent parameters of interest (mass flow rate, vertical depth, horizontal extent, borehole diameter, formation gradient, formation conductivity, and injection temperature). The corresponding numerical solutions (approximately 1.2 million per heat exchanger design) are stored as multi-dimensional HDF5 datasets and can be queried at off-grid points using multi-dimensional linear interpolation. A Python script was developed to query this database and estimate time-dependent electricity generation using an organic Rankine cycle (for water) or direct turbine expansion cycle (for CO2) and perform a cost assessment. This document aims to give an overview of the HDF5 database file and highlights how to read, visualize, and query quantities of interest (e.g., levelized cost of electricity, levelized cost of heat) using the accompanying Python scripts. Details regarding the capital, operation, and maintenance and levelized cost calculation using the techno-economic analysis script are provided. This data submission will contain results from the Closed Loop Geothermal Working Group study that are within the public domain, including publications, simulation results, databases, and computer codes. GeoCLUSTER is a Python-based web application created using Dash, an open-source framework built on top of Flask that streamlines the building of data dashboards. GeoCLUSTER provides users with a collection of interactive methods for streamlining the exploration and visualization of an HDF5 dataset. The GeoCluster app and database are contained in the compressed file geocluster_vx.zip, where the "x" refers to the version number. For example, geocluster_v1.zip is Version 1 of the app. This zip file also contains installation instructions. **To use the GeoCLUSTER app in the cloud, click the link to "GeoCLUSTER on AWS" in the Resources section below. To use the GeoCLUSTER app locally, download the geocluster_vx.zip to your computer and uncompress this file. When uncompressed this file comprises two directories and the geocluster_installation.pdf file. The geo-data app contains the HDF5 database in condensed format, and the GeoCLUSTER directory contains the GeoCLUSTER app in the subdirectory dash_app, as app.py. The geocluster_installation.pdf file provides instructions on installing Python, the needed Python modules, and then executing the app.

15 GEOTHERMAL ENERGY↗

Tabulated Database of Closed-Loop Geothermal Systems Performance for Cloud-Based Technical and Economic Modeling of Heat Production and Electricity Generation: Preprint

To better understand the heat production, electricity generation performance and economic viability of closed loop geothermal systems in hot-dry-rock, the Closed Loop Geothermal Group, a consortium of several national labs and academic institutions has tabulated time-dependent numerical solutions and levelized cost results of two popular closed loop heat exchanger designs (u-tube and co-axial). The heat exchanger designs were evaluated for two working fluids (water and super-critical CO2) while varying seven continuous independent parameters of interest (i.e., mass flow rate, vertical depth, horizontal extent, borehole diameter, formation gradient, formation conductivity, and injection temperature). The corresponding numerical solutions (approximately 1.2 million per heat exchanger design) are stored as multi-dimensional HDF5 datasets and can be queried at off-grid points using multi-dimensional linear interpolation. A Python script was developed to query this database and estimate time-dependent electricity generation using an Organic Rankine cycle (for water) or direct turbine expansion cycle (for CO2) and perform a cost assessment. This document aims to give an overview of the HDF5 database file and highlights how to read, visualize, and query quantities of interest (e.g., levelized cost of electricity, levelized cost of heat) using the accompanying python scripts. Details regarding the capital, operation, and maintenance and levelized cost calculation using the TEA (techno-economic analysis) script are provided.

co-axial↗

Industrial Scale Demonstration of Smart Manufacturing, Achieving Transformational Energy Productivity Gains

While many U.S. manufacturing operations utilize optimization for individual unit processes, smart manufacturing (SM) systems that integrate manufacturing intelligence in real time across an entire production operation are rare in large companies and virtually nonexistent in smaller organizations. One example of an area where SM systems can be applied is in the management of waste heat. A smart system that not only seeks to recover waste heat, but also to use energy more efficiently, is a more cost-effective approach because energy use, waste energy loss and product output are optimized together. The overall objective of this project was to develop an industry-accepted SM Platform that enables smart systems by accelerating and lowering the cost of development and implementation scales for use in diverse sets of manufacturing industry sectors, manufacturing operations and company sizes. Specifically, the project (1) designed and demonstrated the application of a prototype SM Platform for two diverse commercial test beds, (2) demonstrated at one and estimated for the other test bed the potential reduction in waste heat generation, and (3) worked with leading automation vendors to catalyze low-cost commercialization of the technology developed. The Smart Manufacturing Application and Data Platform (SM Platform) developed during this project is an innovative approach that marries IT virtualization technologies with operational data and modeling system requirements to construct a ready-to-go platform for enabling sensor – data – modeling – actuation systems, driven by real-time plant data and performance metrics. This SM Platform allows manufacturing organizations, regardless of their industry or size, to assemble new operational systems at a much lower cost, optimizing process knowledge and improving energy productivity by integrating with existing process control and automation systems. Also developed during this project is a methodology for developing energy productivity metrics that use real-time process information and provide comparisons for potential, practical, and actual performance, as well as examples and the methodology for provisioning of an Energy Dashboard that displays alternatives to optimize energy use within specific business contexts aimed at helping improve energy productivity and reduce emissions in U.S. manufacturing. The SM Platform designed utilizes current manufacturing, operational and IT industry standards. The platform can be used to expedite sensor – data – model – actuation system development and deployment in a cloud-based environment using a novel end-to-end workflow as a service capability that is already integrated with data connection, ingestion, and contextualization services. In addition, the methodology for development of energy productivity metrics and reusable application templates called Toolkits have been defined so that they can be tailored to a specific business situation. The project’s two test beds, one in a hydrogen production plant and the other in a forging, heat treatment, and machining operation, utilize sensor-driven modeling, measurement, and simulation systems. In these two test beds, the implementation of these as a comprehensive system has made it possible for energy productivity to be managed in real-time throughout the plant and enterprise using an energy dashboard. The development pathway to direct machine actuation was articulated. During the first year, the project team developed the most highly instrumented steam-methane reformer (SMR) in the U.S. using infrared cameras and thermocouples. Real-time data are streamed to high fidelity and reduced-order models for analysis. A high fidelity CFD model, parallelized in the SM Platform cloud environment, was demonstrated for operational use. This is the first real-time operational productivity system of a steam methane reformer using both high fidelity and data-driven models together in a real time situation to balance natural gas flow to the reformer tubes. An infrared camera system was developed and shown to outperform thermocouples in coverage, accuracy, reliability, and cost effectiveness for use in a high temperature, harsh environment. A forging, heat-treating, machining line operation test bed includes new instrumentation for data capture analysis, modeling, and simulation and will be integrated into SM Platform workflows so that business performance can be managed in real-time. Composable metrics were developed using the SM Platform to drive improvements in energy productivity, environmental performance, safety, asset management, costs, and overall operations. A major focus of the SM systems developed was optimization of energy productivity at the enterprise level, which resulted in reductions in waste heat generation for the two project test beds. Reductions in the waste heat generated will result in greater energy savings than will waste heat recovery due to inefficiencies in the heat transfer process. For the SMR test bed an efficiency improvement of 1 – 2% with a corresponding waste heat reduction of 5% were demonstrated. It should be noted that the test bed SMR unit had an efficiency of more than 90% as compared to 70 to 80% efficiencies of most SMR units. So implementation of similar SM systems at typical SMR units could yield more than 15 to 25% waste heat reductions. Similarly the forging, heat-treating, machining line operation test bed is a DOE AMO Platinum Level Superior Energy Performance plant with a much higher than typical overall operating efficiency. For this test bed heat integration using recuperators is estimated to result in fuel savings of 15.9% due to waste heat recovery compared to the base case without recuperators with negligible changes in part exit conditions. This results in an 18.9% energy efficiency improvement. The project team estimates that broad multi-sector adoption of the developed technology could reduce waste heat generation by an amount equivalent to 1.3% of total U.S. energy use. This waste heat reduction is associated with 69 million tons reduction in annual carbon dioxide emissions. Other potential benefits include reducing process times, solid and liquid wastes, environmental impacts, and water use. It is estimated that this investment has an anticipated payback period of less than one year in energy-intensive applications. The SM Platform could also reduce the costs of deploying SM systems by 50% in manufacturing operations. Commercialization of the SM Platform will require significant cross-industry collaboration and technology provider market changes. Steps taken toward commercialization included 1) analyzing savings from deployment of the SM Platform and 2) holding SM Platform workshops, webinars, and conferences with targeted individual industry segments, with a focus on small and medium-sized organizations. An upgraded community website has been established as a portal for accessing and distributing information. Most importantly, the SM platform enabling technology developed during this project and its commercialization will continue, evolve and expand under the Clean Energy Smart Manufacturing Innovation Institute (CESMII).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Proposal Improvements That Work

Rocketdyne Propulsion and Power, an operating location of Boeing in Canoga Park, California is under contract with NASA's Marshall Space Flight Center (MSFC) in Huntsville, Alabama for design, development, production, and mission support of Space Shuttle Main Engines (SSMEs). The contract was restructured in 1996 to emphasize a mission contracting environment under which Rocketdyne supports the Space Transportation System launch manifest of seven flights a year without the need for a detailed list of contract deliverables such as nozzles, turbopumps, and combustion devices. This contract structure is in line with the overall Space Shuttle program goals established by the NASA to fly safely, meet the flight manifest, and reduce cost. Rocketdyne's Contracts, Pricing, and Estimating team has worked for the past several years with representatives from MSFC, the local Defense Contract Management Command, and the DCAA to improve the quality of cost proposals to MSFC for contract changes on the SSME. The contract changes on the program result primarily from engineering change proposals for product enhancements to improve safety, maintainability, or operability in the space environment. This continuous improvement team effort has been successful in improving proposal quality, reducing cycle time, and reducing cost. Some of the principal lessons learned are highlighted here to show how proposal improvements can be implemented to enhance customer satisfaction and ensure cost proposals can be evaluated easily by external customers.

Dunn, F.↗

Structures and Materials Experimental Facilities and Capabilities Catalog

The NASA Center of Excellent for Structures and Materials at Langley Research Center is responsible for conducting research and developing useable technology in the areas of advanced materials and processing technologies, durability, damage tolerance, structural concepts, advanced sensors, intelligent systems, aircraft ground operations, reliability, prediction tools, performance validation, aeroelastic response, and structural dynamics behavior for aerospace vehicles. Supporting the research activities is a complementary set of facilities and capabilities documented in this report. Because of the volume of information, the information collected was restricted in most cases to one page. Specific questions from potential customers or partners should be directed to the points of contacts provided with the various capabilities. Grouping of the equipment is by location as opposed to function. Geographical information of the various buildings housing the equipment is also provided. Since this is the first time that such an inventory is ever collected at Langley it is by no means complete. It is estimated that over 90 percent of the equipment capabilities at hand are included but equipment is continuously being updated and will be reported in the future.

Horta, Lucas G.↗

Cloud Algorithm Design and Performance for the 2002 Geoscience Laser Altimeter System Mission

A satellite borne lidar instrument, the Geoscience Laser Altimeter System (GLAS), is to be launched in late 2002 and will provide continuous profiling of atmospheric clouds and aerosol on a global basis. Data processing algorithms have been developed to provide operational data products in near real time. Basic data products for cloud observations are the height of the top and bottom of single to multiple cloud layers and the lidar calibrated observed backscatter cross section up to the level of signal attenuation. In addition the optical depth and vertical profile of visible extinction cross section of many transmissive cloud layers and most haze layers are to be derived. The optical thickness is derivable in some cases from the attenuation of the molecular scattering below cloud base. In other cases an assumption of the scattering phase function is required. In both cases a estimated correction for multiple scattering is required. The data processing algorithms have been tested in part from aircraft measurements used to simulated satellite data. The GLAS lidar observations will be made from an orbit that will allow inter comparison with all other existing satellite cloud measurements.

Spinhirne, J. D.↗

ANALYSIS OF CRYOGENIC PROPELLANT FEED SYSTEMS FOR ELECTROTHERMAL ENGINES.

An analytical investigation was made of the problems associated with the long-term storage and control of flow of cryogenic propellants for electrothermal engines. Storage of 35 to 174 pounds of propellant for three years is made difficult by the high ratio of surface area to storage tank volume, and the resulting high rate of heat leak. Vented and non-vented storage, storage as high pressure gas, and the use of refrigeration were considered. Recommended storage methods are: for ethane and ammonia vented storage - by venting propellant stored in excess of mission requirements; for hydrogen and helium - by non-vented storage of cold supercritical vapor; and for methane by storage as a non-vented two-phase mixture. The optimum propellant density in the storage tank and optimum insulation thickness were also determined. Design charts were developed for hydrogen and helium, for estimating the maximum pressure expected in non-vented storage tanks, as function of mission requirements. Separation of the constituent phases of liquid-vapor mixtures is achieved by throttling the two-phase mixture to a lower pressure (and temperature) and vaporizing the liquid in the mixture by heat exchange with the contents of the storage tank. The time limitations for continuous use of this method are discussed. Linde super insulations SI-44 or SI -91 are recommended for insulation. Precooling the insulation to temperatures below the steady state level with cold helium vapor before or during fueling of the storage tank eliminates the flow of heat to the tank contents during countdown and take-off. The masses, sizes, and power requirements of the recommended systems are low. The controls are simple and reliable. From the equations and charts in this report the components of the system for a particular mission can be sized. Recommendations are given for experimental work required for the development and testing of such components.

ELECTROTHERMAL ENGINE↗