An intelligent fault detection and diagnosis monitoring system for reactor operational resilience: Unknown fault detection
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Mendoza, Mario (ORCID:0000000174884636)↗
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Results for “fault diagnosis”
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Fault detection in a three-phase dab converter
A system and method of fault detection based on a detailed waveform analysis is presented for transient and steady-state fault operation of 3-Φ DAB converter. Main symptoms of the converter during normal and fault conditions have been identified and a unique pattern in DC bias of phase currents under fault mode is noted. The logic-based fault diagnosis scheme is used to detect the fault and identify the faulty transistor.
Rastogi, Sagar K.↗
A physics-based parametric regression approach for feedwater pump system diagnosis
Here in this paper, we assessed the performance of a model-based approach for fault diagnosis of a nuclear power plant feedwater pump system. Physics-based models were constructed to monitor the performance of the system components. Plant data were used for the calibration of the models and subsequently in the diagnosis of abnormal events. We considered two real-time events representing scenarios of a pump fault and component performance degradation. The two events were correctly diagnosed, and the results demonstrated the high detection sensitivity of the physics-based models. Various sensor fault scenarios were simulated to show the capability of the approach to detect and uniquely identify sensor faults. Results for a scenario in which the plant operated in flexible power mode also showed that the diagnostic approach is insensitive to changes of operating conditions, which is one of the advantages of the model-based approach using physics-based models over purely data-driven approach.
73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
A review of computing-based automated fault detection and diagnosis of heating, ventilation and air conditioning systems
We report faults in Heating, Ventilation, and Air Conditioning (HVAC) systems of buildings result in significant energy waste in building operation. With fast-growing sensing data availability and advancement in computing, computational modeling has demonstrated strong capability to detect and diagnose HVAC system faults, hence, ensuring efficient building operation. This paper comprehensively reviews the state-of-the-art computing-based fault detection and diagnosis (FDD) for HVAC systems. Overall, the reviewed computing-based FDD methods are classified as two major approaches: knowledge-based and data-driven approaches. We then identify multiple important topics, including data availability, training data size, data quality, approach generality, capability, interpretability, and required modeling efforts, along with corresponding metrics to summarize the most updated FDD development. Generally, the knowledge-based approaches are further divided as physics-based modeling, Diagnostic Bayesian Network, and performance indicator-based methods while data-driven approaches include supervised learning, unsupervised learning, and regression and statistics-based methods. State-of-the-art FDD development, remaining challenges, and future research directions are further discussed to push forward FDD in practice. Availability of fault data, capability of existing methods to deal with complex fault situations (such as simultaneous faults), modeling interpretability for data-driven methods, and required engineering efforts for physics-based methods are identified as remaining challenges in FDD development. Improving modeling fidelity and reducing modeling efforts are essential for applying physics-based methods in real buildings. Meanwhile, addressing fault data availability, increasing algorithm adaptability, and handling multiple faults are essential to further enhance the applicability of data-driven FDD approaches.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Model Predictive Fault-Tolerant Tracking Control for PDF Control Systems With Packet Losses
In this article, a fault-tolerant tracking control strategy is investigated for nonlinear probability density function (PDF) control systems with the actuator fault, uncertainties, unknown disturbance, and random packet losses. The control input signal dropout and measurement signal dropouts are described as the independent Bernoulli distribution. An adaptive fault diagnosis (FD) observer based on the Lyapunov function is given to simultaneously estimate the fault, disturbance, and state with packet losses. Furthermore, different from the traditional robust fault-tolerant control (FTC), a new active fault-tolerant tracking controller is designed based on the model predictive control framework, which has better adaptive fault-tolerant performance. Finally, the validity of the proposed FTC method has been proved by a simulation study of a papermaking process.
42 ENGINEERING↗
A use-case-driven approach for demonstrating the added value of digitalisation in wind energy
Digitalisation is one of the key drivers for reducing the costs and risks of wind energy. When considering whether to embark on a digitalisation initiative, two key questions arise. The first is what business or operational opportunities might feasibly be addressed and the second is which of the many potential aspects of digitalisation are relevant to those opportunities. In this work, we show how these questions can be answered with a use-case-driven approach, based around a survey aiming to collect and collate the main "pain points" (or everyday challenges) of people in the wind energy sector. Although the relatively low number of participants of the survey (46) means that the results should only be used indicatively, it is still possible to make some general recommendations for priorities for digitalisation efforts in the wind energy sector. Firstly, digitalisation efforts should focus both on supporting people carrying out cross-lifecycle tasks, in particular sharing data, managing data, undertaking general data analyses and accessing data. Tools to do this should deal with varying data formats and naming conventions, make metadata more accessible, define data and metadata standards, make more data publicly available and improve the quality of data. Secondly, efforts should also focus on supporting people in the wind farm operational phase, in particular with failure detection, fault diagnosis, failure rate modelling and predictive maintenance. Solutions to do this should focus on accessible and validated tools for fault detection, cloud or other data pipeline solutions for SCADA data and tools for exhaustive data documentation. Finally, digitalisation efforts should focus on better communicating and helping people become aware of existing solutions and tools, as well as on helping people to exert a stronger influence on possible solutions.
17 WIND ENERGY↗
A propagation-based fault detection and discrimination method and the optimization of sensor deployment
Industrial processes can be affected by faults having a serious impact on operation when not promptly detected and diagnosed. Here in this paper, a propagation-based fault detection and discrimination(PFDD) method is proposed to develop a strategy for fault diagnosis while in the design phase of a system. The PFDD method constructs the system model using the Integrated System Fault Analysis(ISFA) technique. Based on the system model, the propagation of hardware and software faults are simulated qualitatively. Given the results of the simulation, the process by which a fault propagates can be characterized using the qualitative features of system variables including the deviation of the system variables from their expected values, the variation of the system variables over time, and the order in which each variable is influenced during the propagation of the fault. The strategy by which a fault can be detected and discriminated is defined using those features. The PFDD method supports the detection and discrimination of faults in both steady states and transient states. Based on the PFDD method, the optimization of sensor deployment in a system is discussed. A brute force algorithm is developed to examine the system’s capability at diagnosing faults and the cost of sensor deployment for all possible configurations of sensors. The optimal sensor deployment strategy can be derived accordingly. However, the brute force method is only applicable to small-scale systems due to its high computational cost. A genetic algorithm is used to optimize sensor deployment in large-scale systems. The PFDD and sensor deployment optimization methods are applied to the Experimental Breeder Reactor II (EBR-II) for verification.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
Explainable AI for Multivariate Time Series Pattern Exploration: Latent Space Visual Analytics With Temporal Fusion Transformer and Variational Autoencoders in Power Grid Event Diagnosis
Detecting and analyzing complex patterns in multivariate time-series data is crucial for decision-making in urban and environmental system operations. However, challenges arise from the high dimensionality, intricate complexity, and interconnected nature of complex patterns, which hinder the understanding of their underlying physical processes. Existing AI methods often face limitations in interpretability, computational efficiency, and scalability, reducing their applicability in real-world scenarios. This paper proposes a novel visual analytics framework that integrates two generative AI models, Temporal Fusion Transformer (TFT) and Variational Autoencoders (VAEs), to reduce complex patterns into lower-dimensional latent spaces and visualize them in 2D using dimensionality reduction techniques such as PCA, t-SNE, and UMAP with DBSCAN. These visualizations, presented through coordinated and interactive views and tailored glyphs, enable intuitive exploration of complex multivariate temporal patterns, identifying patterns’ similarities and uncover their potential correlations for a better interpretability of the AI outputs. The framework is demonstrated through a case study on power grid signal data, where it identifies multi-label grid event signatures, including faults and anomalies with diverse root causes. Additionally, novel metrics and visualizations are introduced to validate the models and assess the performance, efficiency, and consistency of latent maps generated by VAE, which have been utilized in prior studies for latent space cartography and used as a benchmark in this study, and the emerging TFT architecture under various configurations. These analyses provide actionable insights for model parameter tuning and reliability improvements. Comparative results highlight that TFT achieves shorter run times and superior scalability to diverse time-series data shapes compared to VAE. This work advances fault diagnosis in multivariate time series, fostering explainable AI to support critical system operations.
Explainable AI↗
Fault isolation and fault-tolerant control for nonlinear stochastic distribution control systems with multiplicative faults
Here, in this paper, a fault isolation, diagnosis and fault tolerant control algorithm is proposed for nonlinear multiple multiplicative faults stochastic distribution control systems employing Takagi–Sugeno fuzzy system. To obtain the detailed fault information, a fault detection algorithm is introduced to discover the fault occurrence time. Then a fault isolation observer is built to produce the residual, and the error system is separated to subsystems affected only by disturbance and multiplicative faults. Moreover, a fault estimation scheme is presented to obtain the fault magnitude information. When faults occur, the system output probability density function will deviate from the desired distribution. So the model predictive control fault tolerant control scheme is needed to minimize the impact of faults as much as possible to make sure that the post fault output probability density function track the desired probability density function. The validity of the designed algorithm is demonstrated through a simulation example, where the fault tolerant control algorithm ensures that the system output probability density function still track the given output probability density function despite the complex case of multiple multiplicative faults occurring simultaneously.
42 ENGINEERING↗
Reinforcement Learning for Anomaly Detection in Nuclear Power Plant Operation and Maintenance
In nuclear power plants (NPPs), timely identification of sensor and human errors is critical to ensure safe and efficient plant operations. Anomaly detection models can be employed for this task. However, traditional anomaly detection approaches may have high dependency on labeled datasets and struggle with adaptability in complex, dynamic environments. Reinforcement learning (RL) has demonstrated significant potential in fault diagnosis and anomaly detection; however, its application to anomaly detection in NPPs remains a relatively underexplored research direction. Hence, to address this gap, in this study, we present a novel physics-informed reinforcement learning model, PIRL-AD: Physics-Informed Reinforcement Learning for Anomaly Detection, that integrates domain knowledge from calorimetric equations into the RL framework for enhanced sensor and human error anomaly detection. We evaluate the performance of PIRL-AD against a non-physics informed RL benchmark and a support vector machine (SVM) on data collected from a forced flow loop testbed. Experimental results suggest that PIRL-AD outperforms other baselines on a range of anomalous datasets that include both sensor and human-induced anomalies across key performance metrics, statistically outperforming the RL and SVM benchmarks with respect to geometric mean (respectively, 92.96% vs. 91.06% vs. 83.01%) and F1-score (respectively, 89.23% vs. 86.98% vs. 77.01%). Furthermore, the findings suggest the potential of physics-integrated reinforcement learning models for enhanced anomaly detection performance in NPPs.
Reinforcement learning↗
CAN-D: A Modular Four-Step Pipeline for Comprehensively Decoding Controller Area Network Data
Controller area networks (CANs) are a broadcast protocol for real-time communication of critical vehicle subsystems. Original equipment manufacturers of passenger vehicles hold secret their mappings of CAN data to vehicle signals, and these definitions vary according to make, model, and year. Without these mappings, the wealth of real-time vehicle information hidden in the CAN packets is uninterpretable, severely impeding vehicle-related research, including CAN cybersecurity and privacy studies, aftermarket tuning, efficiency and performance monitoring, and fault diagnosis to name a few. Guided by the four-part CAN signal definition, we present CAN-D (CAN-Decoder), a modular, four-step pipeline for identifying each signal's boundaries (start bit and length), endianness (byte ordering), signedness (bit-to-integer encoding), and by leveraging diagnostic standards, augmenting a subset of the extracted signals with meaningful, physical interpretation. En route to CAN-D, we provide a comprehensive review of the CAN signal reverse engineering research. All previous methods ignore endianness and signedness, rendering them incapable of decoding many standard CAN signal definitions. Incorporating endianness grows the search space from 128 to 4.72E21 signal tokenizations and introduces a web of changing dependencies. In response, we formulate, formally analyze, and provide an efficient solution to an optimization problem, allowing identification of the optimal set of signal boundaries and byte orderings. In addition, we provide two novel, state-of-the-art signal boundary classifiers—both of which are superior to previous approaches in precision and recall in three different test scenarios—and the first signedness classification algorithm, which exhibits a $>$ 97% F-score. Altogether, CAN-D is the only solution with the potential to extract any CAN signal that is also the state of the art. In evaluation on 10 vehicles of different makes, CAN-D's average $\ell ^1$ error is five times better (81% less) than all previous methods and exhibits lower average error, even when considering only signals that meet prior methods’ assumptions. Finally, CAN-D is implemented in lightweight hardware, allowing for an on-board diagnostic (OBD-II) plugin for real-time in-vehicle CAN decoding.
42 ENGINEERING↗
Enabling Efficient Surveillance, Control, and Automation of Geothermal Operations with Advanced Predictive Analytics
Automation and control of geothermal energy production and operations require reliable and efficient predictive tools. While physics-based simulation offers a comprehensive tool for predicting energy production performance in geothermal systems, predicting the behavior of geothermal reservoirs involves complex multi-physics processes with coupling effects, highly uncertain input parameters and subsurface descriptions. Moreover, building, running, and integrating simulation models into standard model calibration and optimization workflows entail significant technical and computational efforts. An emerging alternative to physics-based simulation is data-driven predictive analytics models that have gained popularity in energy industry. In this report, we develop novel predictive models for integration into real-time fault diagnosis and model predictive control algorithms to improve the efficiency of energy production operations in geothermal reservoirs. The report includes two major research Thrust Areas, that is, the surface power plant and the subsurface reservoir.
15 GEOTHERMAL ENERGY↗
Controller area network decoder (CAN-D)
A system and method for decoding an unknown automotive controller area network (“CAN”) message definitions. CAN data vehicle signal mappings are typically held in secret and varied by automotive model and year. Without knowledge of the mappings, the wealth of real-time vehicle data hidden in the automotive CAN packets is uninterpretable—impeding research, after-market tuning, efficiency and performance monitoring, fault diagnosis, and privacy-related technologies. This technology can ascertain the CAN signals' boundaries (start bit and length), endianness (byte ordering), signedness (binary-to-integer encoding) from raw CAN data. This allows conversion of CAN data to time series. Interpreting the translated CAN data's physical meaning and finding a linear mapping to standard units (e.g., knowing the signal is speed and scaling values to represent units of miles per hour) can be achieved for many signals by leveraging diagnostic standards to obtain real-time measurements of in-vehicle systems. The system and method can be integrated into lightweight hardware enabling an OBD-II plugin for real-time in-vehicle CAN decoding or run on standard computers. The system can output a standard DBC file with the signal definition information.
Verma, Kiren E.↗
Power Module Precursors and Prognostics
This project focuses on finding and utilizing electrical properties (precursors) of power electronic devices and modules whose changes have strong correlations with different modes and levels of degradations in order to realize online and lightweight state of health evaluation and fault diagnosis. Results from this project will contribute to higher safety, reliability, and power density of power electronic components. The approaches mainly include reviewing academic literature and industry practices for state of the art precursor identification and extraction, accelerated life cycles (ALC) of various power modules to create different degradations in-house, and developing techniques for gate-driver-integratable precursor detection circuit. In FY24, the results includes two sets of definitively detected aging precursors (on-state resistance and gate threshold voltage) for two sets of power modules respectively, controlled accelerated lifetime cycling of multiple silicon carbide (SiC) metal-oxide-semiconductor field-effect transistor (MOSFET) modules, and the development and validation of a gate voltage detection system.
ADVANCED PROPULSION SYSTEMS↗
System for controller area network payload decoding
A system for decoding an unknown automotive controller area network (“CAN”) message definitions. CAN data vehicle signal mappings are typically held in secret and varied by automotive model and year. Without knowledge of the mappings, the wealth of real-time vehicle data hidden in the automotive CAN packets is uninterpretable—impeding research, after-market tuning, efficiency and performance monitoring, fault diagnosis, and privacy-related technologies. This system can ascertain the CAN signals' boundaries (start bit and length), endianness (byte ordering), signedness (binary-to-integer encoding) from raw CAN data. This allows conversion of CAN data to time series. Interpreting the translated CAN data's physical meaning and finding a linear mapping to standard units (e.g., knowing the signal is speed and scaling values to represent units of miles per hour) can be achieved for many signals by leveraging diagnostic standards to obtain real-time measurements of in-vehicle systems. The system can be integrated into lightweight hardware enabling an OBD-II plugin for real-time in-vehicle CAN decoding or run on standard computers. The system can output a standard DBC file with the signal definition information.
Verma, Kiren E.↗
Literature Review for Sensor Impact Evaluation and Verification Use Cases - Building Controls and Fault Detection and Diagnosis (FDD)
This report summarizes a comprehensive literature review for the selected sensor suites used in building controls and fault detection and diagnostics (FDD), which is a Q2 deliverable of the Sensor Impact Evaluation and Verification project. The project’s overarching goal is to develop a framework for investigating the impact of sensor deployment and configuration for building energy optimization, fault detection and diagnosis (FDD), occupants’ thermal comfort, and potential grid efficiency. While the first phase of the literature review performed in Q1 reviewed the current methods of various sensor selection and placements and their impact, this report focuses on high impactful potential use cases for the selected sensor suites in building control and FDD. The use cases identified in this literature review will be further investigated and be included in the final sensor impact evaluation framework. For the review, the multi-laboratory team reviewed 241 research papers, technical reports, and books to identify existing technologies, the potential impact on energy savings and thermal comfort, and future research opportunities for the selected use cases in building controls and FDD. Along with the literature review, the team conducted a series of interviews with experts in sensors and controls area to identify the state-of-art sensor technologies, and the most impactful use cases in controls and FDD areas. The interview results will also be incorporated with the findings from the literature review in the next quarter, and the final use cases to be evaluated will be selected.
47 OTHER INSTRUMENTATION↗
Dynamic model-based feature extraction for fault detection and diagnosis of a supermarket refrigeration system
With the increasing concerns over climate change and carbon emissions, fault detection and diagnostics (FDD) of low–global warming potential (GWP) refrigerant supermarket refrigeration systems has gained great attention from academic and industrial sectors. Various FDD approaches have been developed to detect, identify, and diagnose faults to save energy, improve food quality, and protect the environment. Here, to mitigate the difficulty of collecting high-quality steady-state operational data in field operations faced by most model-based FDD methods, this study developed dynamic models of a low–GWP refrigerant (CO 2 ) supermarket refrigeration system. The model accuracy was validated using manufacturer data and experimental data. Simulations were conducted to predict the system dynamic response under two common operational faults—evaporator air path blockage fault and the display case door open fault—to identify fault patterns and define key dynamic behavior indexes for supporting FDD algorithm development.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Review: Sensor Impact on Building Controls and Automatic Fault Detection and Diagnosis (AFDD)
This report summarizes a literature review as a Q1 deliverable of the “Sensor Impact Evaluation and Verification” project. This project’s overarching goal is to develop a framework for investigating the impact of sensor deployment and configuration for building energy optimization, fault detection and diagnosis (FDD), occupants’ thermal comfort, and potential grid efficiency.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗