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DOE OSTI2026

Data Management for Digital Twin Implementation: Enhancing Existing SCADA Architecture for INL's CITRC Test Distribution System

The United States power grid will continue to experience stress from aging infrastructure, extreme weather, and increasing loads. In order to strengthen resiliency, researchers need to run tests and simulations that model real-life infrastructure. Idaho National Laboratory (INL) is creating a digital twin of its Critical Infrastructure Test Range Complex (CITRC). CITRC is an at-scale grid testbed which can be configured in utility-realistic distribution scenarios for a variety of tests, such as advanced grid protection and control. A digital twin of this infrastructure would support in-depth tests/simulations without risking physical consequences, before trialing devices under test at-scale. This project focuses on the data acquisition part of constructing a digital twin. It investigates the Supervisory Data Acquisition and Control (SCADA) system of CITRC and explores ways to utilize this system for the twin. Future “ideal” at-scale implementations such as upgraded equipment, modern communication protocols, and automation applications are also explored.

24 - POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

SQuaD: Smart Quantum Detection for Photon Recognition and Dark Count Elimination

Quantum detectors of single photons are an essential component for quantum information processing across computing, communication and networking. Today's quantum detection system, which consists of single photon detectors, timing electronics, control and data processing software, is primarily used for counting the number of single photon detection events. However, it is largely incapable of extracting other rich physical characteristics of the detected photons, such as their wavelengths, polarization states, photon numbers, or temporal waveforms. This work, for the first time, demonstrates a smart quantum detection system, SQuaD, which integrates a field programmable gate array (FPGA) with a neural network model, and is designed to recognize the features of photons and to eliminate detector dark-count. The SQuaD is a fully integrated quantum system with high timing-resolution data acquisition, onboard multi-scale data analysis, intelligent feature recognition and extraction, and feedback-driven system control. Our \name experimentally demonstrates 1) reliable photon counting on par with the state-of-the art commercial systems; 2) high-throughput data processing for each individual detection events; 3) efficient dark count recognition and elimination; 4) up to 100% accurate feature recognition of photon wavelength and polarization. Additionally, we deploy the SQuaD to an atomic (erbium ion) photon emitter source to realize noise-free control and readout of a spin qubit in the telecom band, enabling critical advances in quantum networks and distributed quantum information processing.

Linne, Karl C. [U. Chicago (main)] (ORCID:00090009↗

DOE OSTI2026

Engineering Controls Database

Cyber-Informed Engineering (CIE) addresses the reality that cyber attacks on engineered systems can have consequences far beyond data loss or disruption of digital networks. When control systems are compromised, safety, reliability, and performance of the physical process itself may be threatened. This database is meant to establish clear examples and guidance for defining and applying engineered controls in CIE. It explains what engineered controls are, how they differ from information security measures, and how they are integrated into system design. The goal is to ensure that resilience is engineered into systems from the outset. Unlike cybersecurity protections that defend the digital layer, engineered controls act directly at the physical and algorithmic levels to guarantee that unacceptable consequences are prevented or limited. CIE keeps the consequences of a cyber attack from impacting the safety, reliability, and performance of engineered systems.

Source record↗

DOE OSTI2025

Cyber-Informed Engineering (CIE) – Engineered Controls Database and Use

Cyber-Informed Engineering (CIE) addresses the reality that cyber-attacks on engineered systems can have consequences far beyond data loss or disruption of digital networks. When control systems are compromised, safety, reliability, and performance of the physical process itself may be threatened. This database is meant to establish clear examples and guidance for defining and applying engineered controls in CIE. It explains what engineered controls are, how they differ from information security measures, and how they are integrated into system design. The goal is to ensure that resilience is engineered into systems from the outset. Unlike cybersecurity protections that defend the digital layer, engineered controls act directly at the physical and algorithmic levels to guarantee that unacceptable consequences are prevented or limited. CIE keeps the consequences of a cyber attack from impacting the safety, reliability, and performance of engineered systems.

42 - ENGINEERING↗

DOE OSTI2024

ML based control systems for nuclear physics experiments

The Experimental Physics Software and Computing Infrastructure (EPSCI) group at Jefferson Lab is leading the use of machine learning (ML) to enhance control systems in nuclear physics experiments. Collaborating closely with domain experts and data scientists, we have developed an ML-based control system that uses a Gaussian process to dynamically adjust the high voltage of the GlueX Central Drift Chamber. This results in stable detector performance by adapting to environmental changes, thereby reducing the offline calibration effort. Furthermore, we are developing ML-driven systems for optimizing the polarization of photon beams and polarized cryotargets. These systems will maintain the optimal microwave frequency in cryogenic targets and make real-time adjustments to diamond radiators for polarized photon sources, tasks traditionally handled by human operators. By automating these functions, we aim to optimize the polarization, reduce downtime, and minimize human error. This talk will highlight the development of reliable ML-based control systems and the policies to ensure they are both effective and trustworthy.

Jeske, Torri↗

DOE OSTI2026

Added value of site load measurements in probabilistic lifetime extension: a Lillgrund case study

Site-specific fatigue estimation is an essential part of wind turbine lifetime extension, with various methods depending on data availability. The present study compares probabilistic lifetime extension assessment results for rotor blades with and without load measurements. It also addresses two key questions in such assessments: the applicability of the Frandsen model for estimating waked turbulence under complex and mixed wake conditions and the extrapolation of mid-term data over longer time periods. The case study wind turbine is SWT-2.3-93, located at the edge of the Lillgrund wind farm, situated in the Øresund Strait between Denmark and Sweden. The turbine is extensively instrumented, with 5 years of data available from its supervisory control and data acquisition (SCADA) system. Although the Frandsen turbulence estimates deviate in a different manner from measurements at below- and above-rated mean wind speeds, the model remains a conservative approach for fatigue load prediction and reliability. In the current case study, the site-specific assessment using strain gauge measurements yields a 33 % higher annual fatigue reliability index after 35 years compared to a scenario based on the Frandsen estimation combined with ambient environmental data and a generic aeroelastic model. The results also demonstrate that the sensitivity of fatigue reliability to load uncertainty is negligible when load measurements are used directly but relatively high when relying on the Frandsen model in combination with a generic aeroelastic model. Overall, the high variability of the lifetime extension in different scenarios of data availability and accuracy shows the importance and added value of high-quality measurements combined with wind-farm-level SCADA and a model updated in real time (digital twins).

17 WIND ENERGY↗

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 OSTI2025

Implementation of high-speed data acquisition at DIII-D

Research at the DIII-D National Fusion Facility in San Diego focuses on short pulse plasma discharges that specialize on various shaping profiles. High-speed data collection is a critical component for the operation of many of DIII-D’s diagnostics and is fundamental for capturing high-resolution data used in experimental data analysis. Differing techniques enable the plasma control system (PCS) to perform complex real-time feedback control on microsecond time scales. This work presents a comprehensive overview of data acquisition, focusing on the hardware and software used in reliable data acquisition at DIII-D. The robust nature of the data acquisition system allows for various techniques to coexist seamlessly. However, as modern systems capable of nanosecond resolution become more common, existing architectures will need to be modified. Here, by addressing the key challenges of high-speed data acquisition, DIII-D is able to provide real-time data used in plasma operation and has the ability to acquire high fidelity data needed for future experimental fusion reactors, such as ITER.

Control↗

DOE OSTI2025

Dynamic Boundary Microgrids Under Privatization Considerations

Microgrids have physical, electrical, and logical (data, network, and ownership) boundaries. To power unserved customer loads during an outage, microgrids can extend the traditional operational boundaries. This can become complex when considering microgrid-to-microgrid (M2M) interactions where sensitive information such as competitive microgrid operational data is not shared. This work proposes an optimization method coordinated between microgrid controllers and distribution management systems that limits data sharing. The method involves a competitive bidding strategy that maximizes unserved load coverage while minimizing resource utilization and sensitive operational data sharing among entities. The work is validated on a two-microgrid system with photovoltaic and energy storage systems and curves of load derived from real world residential buildings datasets. Results show that the proposed method, when applied for three distinct use cases of energy storage sufficiency to cover the predefined boundary and/or the expanded boundary, can successfully select and bid the available load coverage.

Starke, Michael [ORNL] (ORCID:0000000221211195)↗

DOE OSTI2024

Nuclear Data Management and Analysis System Plan

The United States Department of Energy Advanced Reactor Technologies Program was formed in Fiscal Year 2015 and encompasses the Next Generation Nuclear Plant Project and Very High Temperature Reactor (VHTR) Program as they were known previously. The VHTR Program was created to support design and licensing of the first VHTR nuclear plant. Data created for and used by the program must be qualified for use, stored in a readily accessible electronic form, categorized to assure the correct data are used, and controlled to prevent data corruption or inadvertent changes. The Nuclear Data Management and Analysis System was designed to support the data needs of the VHTR Program, at the time and now the Advanced Reactor Technologies Program. Since its inception, use of the Nuclear Data Management and Analysis System has expanded to support additional projects and programs with similar requirements for control, analysis, and availability of large data sets.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2026

EPICS for small-scale laboratories with Python soft IOCs

While the Experimental Physics and Industrial Control System (EPICS) is widely used at large laboratories for slow controls and instrumentation, the deployment of a full EPICS installation can be difficult, with a steep learning curve to new users. Taking advantage of the pythonSoftIOC module, we developed an EPICS slow controls implementation for Jefferson Lab's Hall B cryotarget written entirely in Python and based on software IOCs that communicate with instruments over Ethernet. Here, this system ran successfully, interfacing with Jefferson Lab's full EPICS network, and we offer it as an example of the capabilities of pythonSoftIOC to build lightweight, yet robust and flexible instrumentation platforms that would be easily adapted for use at a small-scale laboratory. University groups can use these examples to build complete slow controls systems, from device communication to data archiving and display, using open-source, mature EPICS tools and student-friendly Python as an alternative to expensive and proprietary systems such as LabVIEW.

Computing↗

DOE OSTI2026

Robust Heat-Flux Sensors for Coal-Fired Boiler Extreme Environments

In this project, robust heat-flux measurement systems were developed. The heat-flux sensors utilize thermoelectric effects to directly transduce the heat-flux inputs to analog electrical voltage signals. They were constructed from dedicated materials that can withstand temperatures of at least 1000°C and maintain adequate performance at these conditions for prolonged periods of time. The proposed approaches took into account numerous considerations, including system cost, sensor head resilience, sensor footprint, data accuracy, response time, and maintenance requirements. Through modern thermoelectric materials design, methodical materials selection and rigorous testing in materials characterization labs and medium-scale fire research facilities, we have demonstrated functioning laboratory prototypes, upon which one could base industrial heat-flux sensing platforms capable of operating in the challenging high-temperature, corrosive environments of the boilers of coal-fired power plants. A distributed sensor array for heat-flux measurements throughout the furnace water-wall, the superheater area and the economizer coils can provide critical data for the power plant control systems to increase efficiency, improve safety and reduce down times. For example, the combined heat-flux sensor/control systems can contribute to the optimization of burner and boiler operations under flexible loads, the optimization of heat-exchange conditions and overall reduction of heat rate and emissions, the prediction of imminent overheating conditions, and the optimization of the soot-blowing protocols.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2025

Network Slicing for Federated Learning in Operational Technology Environment

Industrial Control Systems (ICS) and Supervisory Control and Data Acquisition (SCADA) environments are essential to modern infrastructure, facing challenges in ensuring low-latency, high-throughput communication while mitigating cyber threats. This paper presents a framework integrating Federated Learning (FL) and network slicing with Quality of Service (QoS) to enable real-time monitoring without disrupting OT operations. Leveraging digital twin technology and Network Function Virtualization (NFV), the architecture supports predictive analytics and Industry 4.0 requirements. FL facilitates decentralized model training, preserving data privacy and scalability, though it introduces potential throughput constraints. Network slicing addresses this by creating dedicated virtualized segments optimized for performance and security. Advanced fault tolerance at the container and instance levels enhances system reliability. The proposed architecture ensures high throughput, low latency, and secure orchestration for real-time anomaly detection in OT networks. Performance evaluations validate its efficiency in throughput, deployment, and learning accuracy, providing a robust foundation for future ICS automation and data-driven decision-making.

Delgado, Brian G. Rodiles [University of Texas at ↗

DOE OSTI2024

Voltage stability smart meter for analyzing voltage data and controlling an electrical power source and/or an electric appliance

Systems and methods for voltage stability monitoring and active/reactive power support are disclosed herein. In some embodiments, a smart electric meter of an end user in a grid power system can measure the voltage supplied to the end user via the grid power system, and can analyze the voltage data to detect critical voltage characteristics. The critical voltage characteristics may indicate that a voltage collapse event is likely. The smart electric meter can further estimate a voltage stability margin based on the voltage data. If necessary, the smart electric meter can control an electrical power source and/or an electric appliance positioned at or near the end user to increase the voltage stability margin.

Min, Liang↗

DOE OSTI2026

Intelligent Experiments Through Real-time AI: Fast Data Processing and Autonomous Detector Control for sPHENIX and Future EIC Detectors (Final Report)

The overall vision of this project was to integrate real-time artificial intelligence (AI) directly into the data acquisition and detector-control systems of nuclear physics experiments, including both fast online event selection and an autonomous detector-control feedback loop. The work carried out under the award focused on the fast online event-selection half of that vision: the efficient recording of low-momentum heavy-flavor (HF) hadron decays in proton-proton collisions at the sPHENIX experiment at the Relativistic Heavy Ion Collider (RHIC)—an observable that requires fast tracking and topological trigger selection not previously demonstrated at RHIC, and that is essential for QCD studies at future facilities such as the Electron-Ion Collider (EIC). The autonomous detector-control (GPU-based feedback) component named in the project title remained a design concept and was not implemented under this award. The Massachusetts Institute of Technology (MIT) group led the offline simulation and data processing needed to train the machine-learning (ML) models, the translation of trained models to Field-Programmable Gate Array (FPGA) firmware using the hls4ml framework, and the physics validation of heavy-flavor reconstruction. Over the award period, the team developed and hardware-tested the principal components of an AI-based heavy-flavor trigger on simulated and recorded sPHENIX tracker data: a software Bipartite Graph Attention Network (BiGAT) trigger model reaching > 95% signal efficiency at 99% background rejection; an FPGA-native hit clusterizer matching the offline clustering; smaller networks synthesized to FPGA within the required sub-10 µs latency; and an assembled decoder–clusterizer–inference firmware chain exercised on the FELIX readout board. A complete, fully integrated hardware demonstrator was not finished within the award period. This report documents the project goals, the MIT group’s contributions, the technical accomplishments, and the outlook toward applications at the future EIC ePIC detector.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2026

Potential of Data Center Controls in Grid Services

The rapid proliferation of large data centers brings both challenges and opportunities for grid reliability. The data center resources and their potential flexibility have the potential to contribute resources to grid operations. Through capabilities like energy shifting and resource coordination, data centers can help reduce their net demand on the transmission network, as well as provide additional grid services to support reliable operation on the grid. While transient and long-term grid planning and operations are the scenarios that draw most attention, the quasi-steady state timeseries (QSTS) operation of data centers and grid bring interesting scenarios that can help evaluate the data center controls to aid grid services. This work is focused on modeling data centers for QSTS applications – incorporating the AI data center load profiles and building on the PNNL digital twin model for the thermal management loads to enable simulation studies to reveal the impact of data center controls on grid performance. This includes the integration of a QSTS battery and natural gas generator model to incorporate local resource impacts to the system. The simulation study is performed with a modified IEEE 24-Bus transmission system. Scenarios are focused on evaluating the data center load impacts on the transmission system and leveraging both data center and local generation controls to mitigate those impacts and provide additional grid services. The data center controls revealed the ability to contribute to two main kinds of grid services: preventing congestion on a weak grid by coordinating the data center resources with the collocated BESS and onsite generation; and the ability to help the grid operations during stressed times of operation like during a contingency. Leveraging these and other capabilities has the potential to help data centers become grid responsive assets, aiding in both their integration into the power system and grid reliability.

power grid simulation↗

DOE OSTI2026

Engineering Against Digital Risk in CIP Applications: Cyber-Informed Engineering Use Cases

99 - GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Unsupervised anomaly clustering via offset alignment in multivariate grid sensing data

Modern industries increasingly rely on multi-sensor technologies to acquire complex, high-dimensional data streams, enabling advanced monitoring and control systems. One critical application is online anomaly detection in electrical smart grids, where multivariate and multimodal sensing technologies play a vital role. However, detecting anomalies in such time-series data is challenging due to their inherent temporal dependencies and stochastic behavior. Traditional approaches based on supervised and semi-supervised learning methods depend on labeled datasets, which are often unavailable in real-world scenarios. While unsupervised methods have emerged as promising alternatives, these methods are highly susceptible to noise and outliers commonly present in sensing applications. Furthermore, deep learning-based anomaly detection methods, despite their performance, are often criticized for their black-box nature, limiting their applicability in safety-critical and online environments where interpretability and explainability are paramount. In this work, we propose an unsupervised anomaly clustering method leveraging a cyclic alignment-based offset detection algorithm for multivariate time-series signals. The proposed method is applied to multivariate data collected from vibrational, voltage, and magnetic field sensors deployed in a local grid substation. Our results demonstrate the robustness of the algorithm in accurately clustering various anomalies/events across different sensing modalities. Additionally, we compare the effectiveness of the proposed approach against a simple pattern-based anomaly detection method, which performs well for univariate data but fails to generalize to multivariate and multimodal time-series data.

Mukherjee, Subrata [ORNL] (ORCID:0000000309930338)↗