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This presentation provides updates on the work conducted for the Gearbox Reliability Collaborative on the gearbox reliability database, condition monitoring and operations and maintenance research.
In December 2013, Cabrera Services (Cabrera) executed transition of the FUSRAP Maywood Superfund Site remediation project operations, including an on-site accredited environmental lab, from a large business that had established technology infrastructure in place for over a decade which required updating to support the expected remediation scope and client needs. As of November 2015, Cabrera has shipped over 116,000 yd{sup 3} of contaminated soil to disposal facilities. During the transition, the USACE FUSRAP Maywood Laboratory (UFML) continued to support project operations, providing the expected timely and reliable results and maintaining their New Jersey Department of Environmental Protection certification for all parameters of concern, while having to cope with new challenges and additional tasks having the potential to disrupt the laboratory's ability to support project operations. This case study examines the challenges with maintaining a certified radiochemistry laboratory and an aggressive remediation schedule during a period of prime contractor transition which included a complete IT infrastructure overhaul, and conversion of the existing Microsoft Access laboratory database and project Electronic Data Management System (EDMS) to a customized commercial solution. Challenges: I. Procurement of a new database subcontractor and working closely with them to achieve the following: a. Migration of all environmental (including radiological, chemical, and quality control), health and safety, and spatial data as well as reports, queries, and analytical instrument software processes from a MS Access data management system to a SQL server system; and b. Verification that the functionality and data integrity of the databases remained intact. II. The onsite laboratory was changed over to a new onsite network and the following tasks were completed with little or no interruption to site operations by January 10, 2014: i. Installation of new instrument personal computers (PCs) and making them fully operational; ii. Configuration of the lab domain and server to host the LIMS (replaced all servers/domain/workstations with Windows 7 and Server 2012 machines). iii. Networking of the laboratory building into the rest of the project site via fiber optic cabling across the site. iv. Upgrade of the wide area network (WAN) data connection to high-speed Fiber Optic service; v. Upgrade of the telephones into voice over internet protocol (VOIP) phones. vi. Splitting of the database into front ends and a centralized back-end hosted on the new server to allow simultaneous access for fixes and improvements. III. Phone service interruption; phone systems were operational by January 10, 2014. Additional Tasks: I. Revision of the USACE FUSRAP Maywood Laboratory (UFML) Quality Systems Manual Rev. 1 Submitted 01/16/14; II. Writing of the Uniform Federal Policy Quality Assurance Project Plan Rev. 1 (UFP-QAPP) submitted 1/21/14. This document replaced the prior project data quality plan, the Chemical Data Quality Management Plan. III. Support of USACE communications to the New Jersey Department of Environmental Protection (NJDEP) on lab management and personnel transition to Cabrera. This work was important since it ensured a smooth transition and shows how critical project records infrastructure such as databases, can be upgraded with minimal interruption of project support. Such work may provide benefit to other similar projects, especially long term projects where database infrastructure upgrades may be beneficial in terms of improved efficiencies in data recording and transfer, and improved security in data storage. (authors)
Photovoltaic (PV) module backsheets degrade at different rates because of the specific polymeric materials and the local exposure environments of the installations. Studies of real-world backsheet degradation provide valuable information to understand backsheet degradation and failure. Field surveys of PV module backsheets were conducted on 1310 modules in four commercial PV power plant sites with different exposure times. The backsheet's local exposure environment is determined by its location along the rack length and depth, the modules' elevation above the ground, and the ground cover albedo. Backsheets that are installed at the ends of the module rack length exhibit larger degradation rates (with yellowness index difference of 1.14 $\pm$ 0.45 and 7.80 $\pm$ 1.3 for backsheets of poly (ethylene terephthalate) and poly (ethylene naphthalate) as the air-side layer, respectively) than backsheets in the center section of the rack. A generalized spatio-temporal model was developed to predict the large-scale backsheet degradation of different backsheet polymers across time/age and location in the PV power plant rack. The model utilizes a cubic-spline relationship between backsheet degradation and rack length, and a quadratic relationship between backsheet discoloration and rack depth. This generalized spatio-temporal model predicts the outdoor backsheet degradation with an adjusted- $R^2$ range between 0.31 to 0.89. The similarity between this model and the spatial variation of the rear-side irradiance, indicates that the irradiance plays a significant role in outdoor backsheet degradation. The generalized spatio-temporal model can be used to evaluate large scale PV backsheet performance, as well as a guidance for PV site designers and operations and maintenance crews.
Almost half of the total energy used in the U.S. buildings is consumed by heating, ventilation and air conditionings (HVAC) according to EIA statistics. Among various driving factors to energy performance of building, operations and maintenance play a significant role. Many researches have been done to look at design efficiencies and operational controls for improving energy performance of buildings, but very few study the impacts of HVAC systems maintenance. Different practices of HVAC system maintenance can result in substantial differences in building energy use. If a piece of HVAC equipment is not well maintained, its performance will degrade. If sensors used for control purpose are not calibrated, not only building energy usage could be dramatically increased, but also mechanical systems may not be able to satisfy indoor thermal comfort. Properly maintained HVAC systems can operate efficiently, improve occupant comfort, and prolong equipment service life. In the paper, maintenance practices for HVAC systems are presented based on literature reviews and discussions with HVAC engineers, building operators, facility managers, and commissioning agents. We categorize the maintenance practices into three levels depending on the maintenance effort and coverage: 1) proactive, performance-monitored maintenance; 2) preventive, scheduled maintenance; and 3) reactive, unplanned or no maintenance. A sampled list of maintenance issues, including cooling tower fouling, boiler/chiller fouling, refrigerant over or under charge, temperature sensor offset, outdoor air damper leakage, outdoor air screen blockage, outdoor air damper stuck at fully open position, and dirty filters are investigated in this study using field survey data and detailed simulation models. The energy impacts of both individual maintenance issue and combined scenarios for an office building with central VAV systems and central plant were evaluated by EnergyPlus simulations using three approaches: 1) direct modeling with EnergyPlus, 2) using the energy management system feature of EnergyPlus, and 3) modifying EnergyPlus source code. The results demonstrated the importance of maintenance for HVAC systems on energy performance of buildings. The research is intended to provide a guideline to help practitioners and building operators to gain the knowledge of maintaining HVAC systems in efficient operations, and prioritize HVAC maintenance work plan. The paper also discusses challenges of modeling building maintenance issues using energy simulation programs.
The current NASA Space Shuttle auxiliary propulsion system utilizes nitrogen tetroxide (NTO) and monomethylhydrazine (MMH), hypergolic propellants. This use of these propellants has resulted in high levels of maintenance and precautions that contribute to costly launch operations. By employing alternate propellant combinations, those less toxic to humans, the hazards and time required between missions can be significantly reduced. Use of alternate propellants can thereby increase the efficiency and lower the cost in launch operations. In support of NASA's Space Launch Initiative (SLI), TRW proposed a three-phase project structured to significantly increase the technology readiness of a high-performance reaction control subsystem (RCS) thruster using non-toxic propellant for an operationally efficient and reusable auxiliary propulsion system (APS). The project enables the development of an integrated primary/vernier thruster capable of providing dual-thrust levels of both 1000-lbf class thrust and 25-lbf thrust. The intent of the project is to reduce the risk associated with the development of an improved RCS flight design that meets the primary NASA objectives of improved safety and reliability while reducing systems operations and maintenance costs. TRW proposed two non-toxic auxiliary propulsion engine designs, one using liquid oxygen and liquid hydrogen and the other using liquid oxygen and liquid ethanol, as candidates to meet the goals of reliability and affordability at the RCS level. Both of these propellant combinations offer the advantage of a safe environment for maintenance, while at the same time providing adequate to excellent performance for a conventional liquid propulsion systems. The key enabling technology incorporated in both TRW thrusters is the coaxial liquid on liquid pintle injector. This paper will concentrate on only the design and testing of one of the thrusters, the liquid oxygen (LOX) and liquid hydrogen (LH2) thruster. The LOX/LH2 thruster design includes a LOX-centered pintle injector, consisting of two rows of slots that create a radial spoke spray pattern in the combustion chamber. The main fuel injector creates a continuous sheet of LH2 originating upstream of the LOX pintle injector. The two propellants impinge at the pintle slots, where the resulting momentum ratio and spray pattern determines the combustion efficiency and thermal effects on the hardware. Another enabling technology used in the design of this thruster is fuel film cooling through a duct, lining the inner wall of the combustion chamber barrel section. The duct is also acts as a secondary fuel injection point. The variation in the amount of LH2 used for the duct allows for adjustments in the cooling capacity for the thruster. The Non-Toxic LOX-LH2 RCS Workhorse Thruster was tested at the NASA Marshall Space Flight Center's Test Stand 500. Hot-fire tests were conducted between March 08, 2002 and April 05, 2002. All testing during the program base period were performed at sea-level conditions. During the test program, 7 configurations were tested, including 2 combustion chambers, 3 LOX injector pintle tips, and 4 LH2 injector stroke settings. The operating conditions that were surveyed varied thrust levels, mixture ratio and LH2 duct cooling flow. The copper heat sink chamber was used for 16 burns, each burn lasting from 0.4 to 10 seconds, totaling 51.4 seconds, followed by Haynes chamber testing ranging from 0.9 to 120 seconds, totaling 300.9 seconds. The total accumulated burn time for the test program is 352.3 seconds. C* efficiency was calculated and found to be within expectable limits for most operating conditions. The temperature on the Haynes combustion chamber remained below established material limits, with the exception of one localized hot spot. The test results demonstrate that both the coaxial liquid-on-liquid pintle injector design and fuel duct concepts are viable for the intended application. The thruster head-e design maintained cryogenic injection temperatures while firing, which validates the concept for minimal heat soak back. By injecting fuel into the duct, the throat temperatures were manageable, yet the split of fuel through the cooling duct does not compromise the overall combustion efficiency, which indicates that, provided proper design refinement, such a concept can be applied to a high-performance version of the thruster. These hot fire tests demonstrate the robustness of the duct design concept and good capability to withstand off-nominal operating conditions without adversely impacting the thermal response of the engine, a key design feature for a cryogenic thruster.
The goal of this research is to theorize and quantify the relationships between safety and the financial performance of nuclear power plants (NPPs). The Socio-Technical Risk Analysis (SoTeRiA) theoretical framework, which connects the social aspects (e.g., safety culture) and structural features (e.g., safety practices) of an organization with organizational safety and financial risks, is used to theorize the direct and indirect relationships between safety and the financial performance of NPPs. An Integrated Enterprise Risk Management (I-ERM) methodological framework is developed to operationalize SoTeRiA to quantify NPP safety and financial performance in a unified platform where their underlying physical degradation mechanisms, coupled with maintenance performance (considering human and organizational factors), are explicitly incorporated to depict the interconnections and dependencies between safety and financial performance. In this study, NPP safety refers to both occupational safety and system safety (estimated from Probabilistic Risk Assessment, PRA), and financial performance refers to the monetary values associated with NPP operation and maintenance (O&M) strategies. This report covers a case study demonstrating the feasibility of the I-ERM methodological framework. More detailed development of one of the I-ERM modules, i.e., Probabilistic Physics-of-Failure (PPoF) analysis, and its connection with other I-ERM modules is demonstrated in a second case study. The outcome of this research will help NPP decision-makers create cost-saving maintenance strategies while maintaining safety by providing cost- and risk-informed recommendations regarding maintenance work processes and operational strategies.
This report describes the current state of research related to critical aspects of erosion and selected aspects of degradation of secondary components in nuclear power plants. The report also proposes a framework for online health monitoring of aging and degradation of secondary components. The framework consists of an integrated multi-sensor modality system which can be used to monitor different piping configurations under different degradation conditions. The report analyses the currently known degradation mechanisms and available predictive models. Based on this analysis, the structural health monitoring framework is proposed. The Light Water Reactor Sustainability Program began to evaluate technologies that could be used to perform online monitoring of piping and other secondary system structural components in commercial NPPs. These online monitoring systems have the potential to identify when a more detailed inspection is needed using real-time measurements, rather than at a pre-determined inspection interval. This transition to condition-based, risk informed automated maintenance will contribute to a significant reduction of operations and maintenance costs that account for the majority of nuclear power generation costs. There is unanimous agreement between industry experts and academic researchers that identifying and prioritizing inspection locations in secondary piping systems (for example, in raw water piping or diesel piping) would eliminate many excessive in-service inspections. The proposed structural health monitoring framework takes aim at answering this challenge by combining long-range guided wave technologies with other monitoring techniques, which can significantly increase the inspection length and pinpoint the locations that degraded the most. More widely, the report suggests research efforts aimed at developing, validating, and deploying online corrosion monitoring techniques for complex geometries, which are pervasive in NPPs.
The Light Water Reactor Sustainability Program began to evaluate technologies that could be used to perform online monitoring of piping and other secondary system structural components in commercial NPPs. These online monitoring systems have the potential to identify when a more detailed inspection is needed using real-time measurements, rather than at a pre-determined inspection interval. This transition to condition-based, risk informed automated maintenance will contribute to a significant reduction of operations and maintenance costs that account for most nuclear power generation costs. This report describes the current state of research related to ultrasonic guided wave testing and its application to defect detection in commercial nuclear power plants. The report analyses the applicability of the guided wave technology to secondary piping systems and also study the potential for expanding the range of guided wave technology to include bent piping and other piping components. The ultrasonic guided waves can inspect long stretches of straight piping, however more complex geometries such as elbows, welds, and tees are causing spurious reflections and coherent noise which significantly decrease the sensitivity of the technique. The report analyses two approaches to suppression of coherent noise in guided wave systems: advanced signal processing and pattern recognition based on independent component analysis and blind source separation and hardware-based technique of piezoelectric paint which can be used to facilitate the propagation of mechanical stress waves through piping. It is demonstrated on simulated guided wave data that the independent component analysis is capable of separating different coherent noise components and segregating them from useful signal. The piezoelectric paint approach seem to be a viable alternative to the signal processing methods, however it requires significantly more complicated logistics and initial financial outlay. The future efforts will be concentrated on applying the independent component analysis to real-world guided wave data recorded by the guided wave monitoring system installed on the shell of the low-pressure feedwater heater 13A at Exelon Corporation’s Braidwood Nuclear Generating Station. Also, the joint EPRI-INL research efforts will focus on experimental evaluation of piezoelectric paint as a technique to extend the range of guided wave technology.
The Light Water Reactor Sustainability Program was initiated to evaluate technologies that could be used to perform online monitoring of piping and other secondary system structural components in commercial nuclear power plants. These online monitoring systems have the potential to identify when a more detailed inspection is needed using real-time measurements, rather than at a pre-determined inspection interval. This transition to condition-based, risk-informed automated maintenance will contribute to a significant reduction of operations and maintenance costs that account for most nuclear power generation costs. This report describes the current state of research related to ultrasonic guided wave testing and its application to detecting defects in commercial nuclear power plants. The report analyzes the applicability of the guided wave technology to secondary piping systems, as well as studying the potential for expanding the range of guided wave technology to include bent piping and other piping components. The ultrasonic guided waves can inspect long stretches of straight piping; however, more complex geometries such as elbows, welds, and tees are causing spurious reflections and coherent noise, which significantly decreases the sensitivity of the technique. To deal with these limitations, high-definition fiber optic sensors are applied to complex piping geometries, and advanced machine learning algorithms are used to detect deviations from healthy states. This report also analyzes the performance of advanced signal processing and machine learning-based pattern recognition algorithms in detecting defects in secondary structures. It is demonstrated on guided wave data collected at nuclear power plants that the independent component analysis can separate different coherent noise components and segregate them from useful signals. It also demonstrates that advanced machine learning techniques, such as neural networks, support vector machines, and deep learning networks, can detect minor defects present in inspected structures. Recommendation about the applicability of advanced machine learning techniques to online piping monitoring are also given.
The nuclear industry is pursuing microreactors that can be factory assembled and deployed to remote regions for reliable power generation. One class of microreactors uses a monolithic metal core block coupled to heat pipes for heat rejection, which results in significant thermal stresses in the monolithic structures. This work describes the initial characterization and test plan for evaluating stainless steel test articles fabricated with embedded sensors for measuring heat pipe performance limits, as well as spatially distributed temperatures and strains during electrically heated thermal testing. The electrically heated testing will be performed in the non-nuclear Microreactor Agile Non-Nuclear Testbed and Single Primary Heat Extraction and Removal Emulator facilities located at Idaho National Laboratory. The goals of these tests are to (1) accurately monitor temperature and strain distributions that result from differential thermal expansion in the test articles and (2) quantify heat rejection limits of heat pipes as a function of operating temperature and working fluid during steady-state and transient operations. More generally, the ability to monitor component and system health during microreactor operation is attractive for providing a high sensor density to inform a limited number of microreactor operators to ultimately reduce operation and maintenance costs and move toward semi-autonomous operation. This report discusses the characterization of embedded thermocouples and fiber optic sensors in relevant test articles, including cylindrical pipes and hexagonal monolithic test articles for heat pipe-based reactors. The sensors were embedded by placing them in machined channels and then building up additional material by using ultrasonic additive manufacturing (UAM). UAM is a solid-state welding process that uses downward pressure and a lateral scrubbing motion to bond thin metal foils to a base material layer by layer. The ultrasonic welding process relies on the plastic deformation of the metal—as opposed to typical melting and solidification—to break oxide scales and bond the metal layers. The characterization of these embedded sensors included evaluating fiber optic signal attenuation, observing residual strain in the fibers, investigating microstructural and mechanical aspects, and demonstrating the sensors under various thermal loads and acoustic vibrations. Post-embedding characterization showed a fine grain structure (<1 μm) near the interfaces of the bonded foils as a result of severe deformation from the welding process. A large increase in hardness was observed at the foil interfaces and the fiber/matrix interface compared with the bulk matrix. Even when compared with the SS304 interfaces, the higher hardness observed around the embedded fiber suggests a higher degree of deformation due to the soft metal coating around the silica fiber core. The distributed fiber-optic temperature sensors and embedded thermocouples reliably measured temperature distributions during steady-state and transient thermal testing. The embedded fiber-optic sensors reliably measured strain during both transient and steady-state testing and properly identified resonant frequencies during acoustic testing.
A model of the wind flow conditions around Kennedy Space Center (KSC) Vehicle Assembly Building (VA B) is presented. An incompressible Navier-Stokes flow solver was used to compute the flow field around fixed Launch Complex 39 (LC-39) buildings and structures. The 3-D flow field. including velocity magnitude and velocity vectors, was established to simulate the localized wind speeds and directions at specified locations in and around LC-39 buildings and structures. The results of this study not only help explain the physical phenomena of the flow patterns around LC-39 buildings but also are useful to the Shuttle personnel. Current Operations and Maintenance Requirements and Specifications (OMRS) for vehicle transfer operations are based on empirically derived historical data, and no detailed mathematical analysis of wind conditions around LC-39 structures has ever been accomplished.
Physical security requirement of nuclear power plants (NPPs) in the US is regulated in a mainly prescriptive manner. This “one size fits all” approach may consequently overlook plant-specific characteristics which are beneficial for the inherent safety and security of the plant. Although a performance-based security measure has been promulgated in 10 CFR 73.55(r), current evaluation methods generally emphasize static and conservative assumptions on physical security uncertainties. This conservatism contributes to the overall operational and maintenance costs, which account to 70% of total operating expenditures for an NPP. This paper describes an ongoing work at the Idaho National Laboratory within the Light Water Reactor Sustainability pathway, which aims to optimize physical protection system with regards to system effectiveness and dollar costs. To achieve this goal, a risk-informed approach to physical security is proposed. This approach leverages the Event Modeling Risk Assessment using Linked Diagrams (EMRALD) tool to model facility infiltration and Force-on-Force (FoF) engagement in a dynamic manner. The dynamic FoF analysis was conducted by coupling human performance uncertainties modeled in EMRALD to existing commercial 3-dimensional FoF software, i.e. SCRIBE3D, AVERT and Simajin. Meanwhile, risk analysis was accomplished by coupling the attack outcomes to existing plant Probabilistic Risk Assessment (PRA) model with FLEX strategy. This approach reduces the conservatisms in security modeling and further acknowledges the possibility for plant operators to mitigate the attack outcomes. A sabotage attack on a hypothetical NPP facility was devised to demonstrate the proposed methodology. Dynamic FoF rules were implemented in EMRALD coupled to SCRIBE3D. This dynamic evaluation revealed an additional 21% system effectiveness in protecting the target set relative to the static modelling approach. Furthermore, the conditional core damage probability could be reduced by up to 46% by crediting operator actions in mitigating the sabotage outcomes. We evaluated the relative importance of each component of the physical security posture included in the model and assessed tradeoffs between components to identify potential opportunities for cost reduction while maintaining a specific level of system effectiveness. Results of the cost analysis will be presented in the conference. This study is expected to help NPP operators in allocating resources optimally to satisfy the security requirements.
Modern data science and processing require the use of modern maintenance records. With traditional record-keeping practices, the isolated nature of the data, as well as the presence of handwritten maintenance work orders and incomplete service logs, severely limit the amount of progress that can be made towards advanced condition-based maintenance. These condition-based methods of diagnostics, prognostics, and maintenance planning are a primary goal of next-generation plant operations and maintenance strategies, and are all dependent on the availability of quality plant data including maintenance data. By implementing changes to maintenance record-keeping practices, such as the use of a computerized maintenance management system, key data will become available to allow for implementation of state-of-the-art data analysis methods. This paper covers the benefits of utilizing digital record systems to increase maintenance data availability in terms of condition-based maintenance and asset management. The ability of these methods to enable state-of-the-art practices within industrial organizations is discussed to offer insight into ways that these improvements to operating strategy will contribute to improvements in world-class maintenance excellence. A discussion of the future of asset management in terms of data analytics, maintenance decision support, and data integration is provided to illustrate the changing landscape of plant management. The result is an examination of innovative maintenance strategies and discussion of challenges related to the future of asset management and implementing modern maintenance practices. (authors)
Several Nuclear Power Plant (NPP) operators in USA have announced to close their plants despite there are remaining years on their operating licenses. The cause of these closures is because the plant operators suffer financial losses. Approximately 80% of USA NPPs would have undergone financial losses if they were situated in a deregulated electricity market. In a deregulated market, electricity generators are independent entities separate from the transmission companies and Independent System Operator (ISO) which manages the market. NPPs in this market are termed merchant NPPs, and their profitability is determined solely from electricity generation revenues. Meanwhile, regulated and public power nuclear units’ profitability is determined by the regulatory process in place for each unit. Due to the complexity of differentiating each regulated and public power NPP’s regulations 36 NPPs are at an immediate risk of retiring early to stop losses, while 27 units will likely to follow in the long run. Today, cost is well-recognized and important factor in NPP decision-making that cannot be ignored. Therefore, it is essential to consider risk and cost together in decision-making to strengthen the position of the nuclear industry in an economically challenging energy market. With operational and maintenance (O&M) cost at 70% of the total operating expenditure of an NPP and some plants closing prematurely despite excellent safety record, there is an urgent need to address the high O&M cost. One of the novel entities that provide additional safety resulting in reduced risk of nuclear power plants is Flex equipment. Flex strategies were postulated by the US NRC in the wake of Fukushima Dai-chi accident to address beyond design-basis accidents and improve plant flexibility. Flex strategy comprise both onsite and off-site component storage for the provision of additional materials and equipment. This work explored innovative ways of utilizing the onsite Flex equipment during regular plant operation, for purposes in addition to the intended use of beyond design basis accidents. This report describes the risk and cost analysis of using Flex equipment during regular or unplanned maintenance.
This CALiPER report focuses on lumen maintenance, chromaticity maintenance, and catastrophic failure in 32 of the Series 20 LED PAR38 lamps and 8 benchmark lamps, which were monitored for nearly 14,000 hours at ambient temperatures between 44°C and 45°C.
One of the major contributors to the total operating costs of domestic nuclear fleet of reactors today is the operation and maintenance (O&M) costs. These include labor-intense preventive maintenance programs involving manually-performed inspection, calibration, testing, and maintenance of plant assets at periodic frequency and time-based replacement of assets at periodic frequency, irrespective of their conditions. This has resulted in a labor-centric business model to achieve high capacity factors. To build an optimal maintenance program, it’s time to transition from this labor-centric business model to a technology-centric business model. Fortunately, there are technologies (advanced sensor, data analytics, and risk assessment methodologies) that will support this transition. The technology-centric business model will result in significant plant life extension and reduction of time-based maintenance activities. This will drive down O&M costs as labor is a rising cost and technology is a declining cost. This approach will lay the foundation for real-time condition assessment of plant assets, allowing condition-based maintenance to enhance plant safety, reliability, and economics of operation. The goal of this project is to address challenges in the area of digital monitoring, i.e., the application of advanced sensor technologies (particularly wireless sensor technologies) and science-based data analytic capabilities to advance online monitoring and predictive maintenance in nuclear plants to improve plant performance (efficiency gain and economic competitiveness). To achieve the project goal, in partnership with Exelon Generating Company (Exelon), researchers from Idaho National Laboratory (INL) and Oak Ridge National Laboratory (ORNL) are performing research and development (R&D) to demonstrate application of wireless sensors using the distributed antenna system and advanced data analytics to achieve predictive maintenance. In the report, wireless vibration sensors, vibration data and its indicator are described. The wireless vibration sensors presented in this report support three types of wireless communication, namely, Wi-Fi, cellular, and 900 MHz. These wireless vibration sensors are considered by partner plant site for installation on plant asset to enable online vibration monitoring to replace periodic measurements. These vibration data along with other plant process data will be utilized to develop diagnostic and prognostic models.
High-temperature advanced reactors under development, such as sodium fast reactors (SFR) and molten salt cooled reactors (MSCR), are expected to offer lower levelized cost of energy (LCOE) compared to existing light water reactor (LWR’s). In the existing light water reactors (LWR’s), operation and maintenance (O&M) expenses constitute the largest fraction of the total operating cost. Some of the O&M costs are related maintenance of sensors which can fail due to exposure to harsh environment in a reactor. The O&M costs of Advanced Reactor (AR)’s are expected to constitute a significant fraction of the total cost as well, because of high temperature and radiation level in AR are likely to cause material fatigue and premature failure of sensors and components. The O&M costs in AR’s could be reduced through integration of advanced informatics of performance-related sensors into a digital twin designed for reactor monitoring. For example, machine learning (ML) could be employed for real-time validation and correction of performance-related sensors, and reducing the number of performance-related physical sensor units through virtual sensing. As part of the effort, we investigate real-time validation of thermal hydraulic sensors through one-step ahead forecasting of sensor values using long short-term memory (LSTM) recurrent neural networks (RNN). The sensors are installed in a flow loop containing a thermal mixing tee, which is a common experimental model to study thermal fatigue in a thermal hydraulic loop. In addition, nonlinear transients generated in a thermal mixing tee constitute a good challenge data set for training and validation of ML algorithms. Sensors in this study include thermocouples, flow meters, and optical fibers for distributed temperature sensing. In one experiment, measurement data sets were obtained for a loop was filled with water, and in another experiment, measurements were performed on a loop filled with liquid metal Galinstan. We have also conducted preliminary investigation of one-step ahead prediction of fiber optics-based distributed temperature sensing with LSTM networks. In predicting fiber-based temperature measurements, we treated each gauge pitch of the fiber as an independent sensor. Accuracy of one-step ahead forecasting was estimated by calculating root mean square error (RMSE) for the test segment of time series of each sensor. RMSE’s for temperature sensors in water loop were, for the most part, lower than for the same sensors in Galinstan loop. The RMSE’s for flow meters were similar for both loops. The RMSE’s for distributed temperature measured with the fiber optic sensor were similar to those of the point sensors. Results of this study demonstrated the capability of LSTM one-step ahead forecasting with RMSE comparable to uncertainty in sensor measurements.
Recommendations for logistics activities and logistics planning are presented based on the assumption that a system prime contractor will perform logistics functions to support all program hardware and will implement a logistics system to include the planning and provision of products and services to assure cost effective coverage of the following: maintainability; maintenance; spares and supply support; fuels; pressurants and fluids; operations and maintenance documentation training; preservation, packaging and packing; transportation and handling; storage; and logistics management information reporting. The training courses, manpower, materials, and training aids required will be identified and implemented in a training program.