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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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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

GMS Station SOH Monitoring Configuration Guide (V.1.2)

The GMS Station State-of-Health (SOH) monitoring capability provides the system controller the ability to view current SOH values and calculated statistics for stations and channels, view trend plots of SOH values, be notified when station SOH status changes, and acknowledge or quiet notifications while the station issues are being investigated. The SOH monitoring capability includes components to acquire CD 1.1 protocol station data, extract SOH information from the raw data packets, process the raw SOH information for display, store the SOH information, and display the SOH information in an interactive display. All these components use system and processing configuration to provide the system controller mission-relevant information about station health. This document is a guide to setting the processing configuration for GMS SOH monitoring.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Beowulf v2.5.3 User Guide: Revision 5

This document is a user guide for the Beowulf (rebranding of Watchmen) tool. It describes how operators can access and utilize the application's functionality. Beowulf is a research software application developed by Pacific Northwest National Laboratory (PNNL) that incorporates the scientific and operational expertise for reviewing data from treaty monitoring radionuclide stations. These stations are part of a worldwide network to monitor for nuclear explosions, and the data they produce are critical to make the determination of whether a sample is from a nuclear explosion or some other source (i.e., nuclear reactor or medical isotope production facility). Stations deliver their measurements and system status to the International Monitoring System (IMS), which forwards it via email to all subscribers. Beowulf is capable of processing data from several radioxenon station types and development is in progress on a solution for particulate stations. Screening of data in Beowulf may be done by a number of different users such as radionuclide analysts, evaluators, and data quality experts. This guide is provided to assist those users in navigating the application. The term Beowulf is used generically throughout this document to refer to any of the various components in the software application. The user interface that is viewed with a web browser is the primary focus of this user guide. Other components include a database to store measurements and state of health (SOH) data; and the data loader that monitors incoming emails, parses the data, populates the database, does the initial analysis, and routes data for review.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Development of a health monitoring framework: Application to a supercritical pulverized coal-fired boiler

In this study, this work details the development of a physics-based equipment health monitoring framework for a supercritical boiler, using first-principles models to estimate the remaining useful life (RUL) of its components. The framework accounts for fatigue and creep life consumption, generating spatio-temporal variations in mechanical and thermal stress. Analysis of the stress profile throughout the boiler highlights the finishing superheater inlet steam header as a vulnerable location susceptible to damage from cycling operation. The framework also yields quantified uncertainty in the RUL projection for specific locations, accounting for uncertainties in material properties and boiler operation. Results indicate that operational uncertainties (e.g., seasonal variation and operational strategy) and material properties (e.g., rupture time coefficients, Young’s modulus, yield strength, and coefficient of thermal expansion) significantly impact the RUL of the finishing superheater inlet steam header. Additionally, case studies demonstrate the use of the health monitoring framework as a predictive tool for operational planning under uncertainty, including scenarios with and without updates on the operation of the boiler.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Health Assessment and Performance Monitoring of Large Machine Diagnostics

Presentation to be given at the CCS-6 Statistical Seminar Series. Regularly maintained and operated diagnostic machines are a backbone of data collection and are a vital component of the Stockpile Stewardship Program’s efforts to better understand nuclear physics. The Cygnus X-ray machine, stationed at the Nevada National Security Site’s U1a underground facility, is one such diagnostic that provides a radiographic capability for the subcritical experiment program. Component failures within Cygnus can result in catastrophic downtime for the diagnostic, affecting performance, schedules, and cost. However, over the years various measurements have been collected on the two Cygnus axes, including voltage and current measurements at different locations, which we believe have predictive power to indicate machine health. We will share preliminary insight into this data and the machine learning approaches we are taking to assess Cygnus’ health, observe declining performance, and predict failures.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Application of Margin-Based Methods to Assess System Health

Health management of complex systems such as nuclear power plants is an essential task to guarantee system reliability. This task can be greatly enhanced by constantly monitoring asset status and performances and process such data (through anomaly detection, diagnostic, and prognostic computational algorithms) to identify asset degradation trends and faulty states. While such information and data are typically available for many of the assets, they are not propagated from the asset to the system level in order to identify the most critical assets and prioritize maintenance and surveillance activities. The main reason is driven by the fact that current reliability modeling techniques are inadequate to process such information/data. This is due to the nature of these techniques which are based on the concept of failure rate/probability that do not serve an operational context where quantitative asset health information is available. Simply stated, current reliability techniques serve a run-to-failure operational setting and not a predictive maintenance one where the goal is to perform maintenance and surveillance activities only when they are needed based on asset health. The risk informed asset management (RIAM) project is focusing on the development of a different kind of reliability modeling techniques designed to adequately serve a predictive operational setting. Such reliability techniques move aways from a failure rate/probability to a margin-based mindset where margin is here used as a metric to quantify asset health based only on current and past operational experience of the asset under consideration. In addition, margin-based reliability techniques are able to propagate asset health information from the component to system level and provide importance measure to each asset. This report summarizes a recent activity performed in collaboration with plant modernization pathway designed to integrate monitoring data into margin-based reliability models. Such activity focuses on a specific system of an existing nuclear power plant where large amount of historic monitoring data is used to monitor asset and system health.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Correlating Time-Resolved Pressure Measurements With Rim Sealing Effectiveness for Real-Time Turbine Health Monitoring

Purge flow is bled from the upstream compressor and supplied to the under-platform region to prevent hot main gas path ingress that damages vulnerable under-platform hardware components. A majority of turbine rim seal research has sought to identify methods of improving sealing technologies and understanding the physical mechanisms that drive ingress. While these studies directly support the design and analysis of advanced rim seal geometries and purge flow systems, the studies are limited in their applicability to real-time monitoring required for condition-based operation and maintenance. As operational hours increase for in-service engines, this lack of rim seal performance feedback results in progressive degradation of sealing effectiveness, thereby leading to reduced hardware life. To address this need for rim seal performance monitoring, this study utilizes measurements from a one-stage turbine research facility operating with true-scale engine hardware at engine-relevant conditions. Time-resolved pressure measurements collected from the rim seal region are regressed with sealing effectiveness through the use of common machine learning techniques to provide real-time feedback of sealing effectiveness. Two modeling approaches are presented that use a single sensor to predict sealing effectiveness accurately over a range of two turbine operating conditions. Here, the results show that an initial purely data-driven model can be further improved using domain knowledge of relevant turbine operations, which yields sealing effectiveness predictions within 3% of measured values.

42 ENGINEERING↗
DOE OSTI2021

Correlating Time-Resolved Pressure Measurements With Rim Sealing Effectiveness for Real-Time Turbine Health Monitoring

Purge flow is bled from the upstream compressor and supplied to the under-platform region to prevent hot main gas path ingress that damages vulnerable under-platform hardware components. A majority of turbine rim seal research has sought to identify methods of improving sealing technologies and understanding the physical mechanisms that drive ingress. While these studies directly support the design and analysis of advanced rim seal geometries and purge flow systems, the studies are limited in their applicability to real-time monitoring required for condition-based operation and maintenance. As operational hours increase for in-service engines, this lack of rim seal performance feedback results in progressive degradation of sealing effectiveness, thereby leading to reduced hardware life. To address this need for rim seal performance monitoring, the present study utilizes measurements from a one-stage turbine research facility operating with true-scale engine hardware at engine-relevant conditions. Time-resolved pressure measurements collected from the rim seal region are regressed with sealing effectiveness through the use of common machine learning techniques to provide real-time feedback of sealing effectiveness. Two modelling approaches are presented that use a single sensor to predict sealing effectiveness accurately over a range of two turbine operating conditions. Results show that an initial purely data-driven model can be further improved using domain knowledge of relevant turbine operations, which yields sealing effectiveness predictions within three percent of measured values.

Compressors↗
DOE OSTI2022

Data-driven modeling of power generation for a coal power plant under cycling

Increased penetration of renewables for power generation has negatively impacted the dynamics of conventional fossil fuel-based power plants. The power plants operating on the base load are forced to cycle, to adjust to the fluctuating power demands. This results in an inefficient operation of the coal power plants, which leads up to higher operating losses. To overcome such operational challenge associated with cycling and to develop an optimal process control, this work analyzes a set of models for predicting power generation. Moreover, the power generation is intrinsically affected by the state of the power plant components, and therefore our model development also incorporates additional power plant process variables while forecasting the power generation. We present and compare multiple state-of-the-art forecasting data-driven methods for power generation to determine the most adequate and accurate model. We also develop an interpretable attention-based transformer model to explain the importance of process variables during training and forecasting. The trained deep neural network (DNN) LSTM model has good accuracy in predicting gross power generation under various prediction horizons with/without cycling events and outperforms the other models for long-term forecasting. The DNN memory-based models show significant superiority over other state-of-the-art machine learning models for short, medium and long range predictions. The transformer-based model with attention enhances the selection of historical data for multi-horizon forecasting, and also allows to interpret the significance of internal power plant components on the power generation. This newly gained insights can be used by operation engineers to anticipate and monitor the health of power plant equipment during high cycling periods.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Component Reliability R&D

A review of the work done on the hydrogen Component Reliability R&D project in the last year. The National Renewable Energy Laboratory's (NREL) Hydrogen Safety Research and Development (HSR&D) program in collaboration with the University of Maryland's Systems Risk and Reliability Analysis Laboratory (SyRRA) are working to improve reliability and reduce risk in hydrogen systems through the use of use quantitative data on component leaks and failures, together with Prognosis and Health Management (PHM), and Quantitative Risk Assessment (QRA).

component↗
DOE OSTI2025

Capturing Historic Reliability Performance Through Graph Databases: A Model Based System Engineering Approach

With the goal of improving the performance and reliability of high dependable technological systems such as nuclear power plants, advanced monitoring and health management systems are employed to inform system engineers on observed degradation processes and anomalous behaviors of assets and components. This information is captured in the form of large amount of data which can be heterogenous in nature (e.g., numeric, textual). Such large data availability poses challenges when system engineers are required to parse and analyze them in order to track historic reliability performance of assets and components. This paper tackles directly this challenge by providing means to organize data in the form of a graph: a knowledge graph. The presented approach distinguish itself from current knowledge graph-based methods by the fact that model-based system engineering (MBSE) models are used to “put data into context”. In particular, MBSE models are used as skeleton of a knowledge graph; numeric and textual data elements, once processed, are associated to MBSE model elements. Thus, a knowledge graph captures both system architecture (though MBSE models) and health/performance data. Such feature opens the door to new data analytics methods designed to identify causal relations between observed phenomena.

97 - MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Multi-Level Structural Damage Characterization Using Sparse Acoustic Sensor Networks and Knowledge Transferred Deep Learning

Standard structural health monitoring techniques face well-known difficulties for comprehensive defect diagnosis in real-world structures that have structural, material, or geometric complexity. This motivates the exploration of machine-learning-based structural health monitoring methods in complex structures. However, creating sufficient training data sets with various defects is an ongoing challenge for data-driven machine (deep) learning algorithms. The ability to transfer the knowledge of a trained neural network from one component to another or to other sections of the same component would drastically reduce the required training data set. Also, it would facilitate computationally inexpensive machine learning based inspection systems. In this work, a machine-learning-based multi-level damage characterization is demonstrated with the ability to transfer trained knowledge within the sparse sensor network. A novel network spatial assistance and an adaptive convolution technique are proposed for efficient knowledge transfer within the deep learning algorithm. Proposed structural health monitoring method is experimentally evaluated on an aluminum plate with artificially induced defects. It was observed that the method improves the performance of knowledge transferred damage characterization by 50% during localization and 24% during severity assessment. Further, experiments using time windows with and without multiple edge reflections are studied. Results reveal that multiply scattered waves contain rich and deterministic defect signatures that can be mined using deep learning neural networks, improving the accuracy of both identification and quantification. In the case of a fixed sensor network, using multiply scattered waves shows 100% prediction accuracy at all levels of damage characterization.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Bridging Equipment Reliability Data and Robust Decisions in a Plant Operation Context

In order to reduce operation and maintenance (O&M) costs, nuclear power plants (NPPs) are moving from corrective and periodic maintenance to predictive maintenance strategies. Such transition requires changes on the data that needs to be retrieved and on the type of decision processes to be employed. Advanced monitoring and data analysis technologies are essential to support predictive strategies. They can in fact provide precise information about health of a component, track its degradation trends, and provide information of its expected failure time. With such information, maintenance operations for a component can be performed right before its expected failure time. This dynamic context of O&M operations requires new methods to analyze data, propagate component health information from the component to the system level, and optimize plant resources. In this respect, the risk informed asset management (RIAM) project has been tasked to develop and test this new class of methods into a risk analytics toolset. This toolset consists of data analytics tools coupled with reliability methods designed to manage plant assets and performances in a predictive maintenance context. This report shows the latest improvements on such development and the initial testing of our methods on the three main research areas that the RIAM project is focusing on. These areas are the following: equipment reliability data analytics, system reliability modeling, and plant resources optimization methods. We show how the methods developed in these areas can support predictive maintenance strategies by: 1) analyzing equipment reliability data (either in numeric and textual form), 2) assessing component and system health through an innovative margin-based reliability approach, and 3) identifying the most critical components and set optimal maintenance schedule based on plant economic and operational constraints.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Risk-informed Graded Approach for Reliability and Performance Assessment of Sensor and Instrumentation Systems within Advanced Condition Monitoring Technologies

Advanced condition monitoring (ACM) technologies, such as digital twins, are innovative strategies designed to provide real-time health insights, including the remaining useful life of components. The primary goal of ACM is to predict and alert operators to potential functional failures before they occur. ACM systems achieve this by integrating predictive models with various sensor instrumentation, analog-to-digital converters, data warehouses, and data pre-processors. These sensor and instrumentation systems (SIS) are essential for forming a comprehensive understanding of component conditions and ensuring the predictive success of ACM programs. Introducing new technologies like ACM involves varying degrees of risk that can impact plant reliability. Therefore, risk mitigation should be commensurate with the performance and reliability of the developed technology, following a risk-informed graded approach (RIGA). Establishing a RIGA process requires a clear understanding of the hazards and reliability of all subsystems, including their interdependencies and potential impacts on the overall system. Given the critical role of SIS in ACM, this work reviews hazard identification and reliability quantification methods for SIS. It also considers these methods' implications when developing a RIGA process for ACM.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Multifunctional Fiber-Reinforced Polymer Composites for Damage Detection and Memory

Self-structural health monitoring (SHM) functionalities for fiber-reinforced polymer composites have become highly sought after to ensure the structural safety of newly advancing components in the automotive, civil, mechanical, and aerospace industries. This paper introduces a self-damage detection and memory (SDDM) hybrid composite material, where the structural carbon fiber tow is transformed into a piezoresistive sensor network, and the structural glass fiber operates as electrical insulation. In this study, SDDM specimens were fabricated, and tensile and impact tests were performed. The tensile tests of SDDM specimens find two distinct loading peaks: first where the carbon fiber fails, and second where the glass fiber fails. A linear correlation was observed between the carbon fiber resistance and composite strain up to a threshold, beyond which a sharp nonlinear increase in resistance occurred. The resistance then approached infinity, coinciding with the first loading peak and failure of the carbon fiber elements. This demonstrates the potential for a damage early warning threshold. Additionally, the effect of stitching the sensor tow in a zig-zag pattern over a large area was investigated using tailored fiber placement (TFP) of 1-loop, 3-loop, and 5-loop specimens. Tensile testing found that increasing the number of loops improved the sensor’s accuracy for strain sensing. Furthermore, impact tests were conducted, and as the impact energy progressively increased, the sensor resistance permanently increased. This illustrates a capability for self-memory of microdamage throughout the life cycle of the structure, potentially useful for predicting the remaining life of the composite.

Demo, Luke B. (ORCID:0000000208806522)↗
DOE OSTI2021

Classification and regression models of audio and vibration signals for machine state monitoring in precision machining systems

Here we present a data-driven method for monitoring machine status in manufacturing processes. Audio and vibration data from precision machining are used for inference in two operating scenarios: (a) variable machine health states (anomaly detection); and (b) settings of machine operation (state estimation). Audio and vibration signals are first processed through Fast Fourier Transform and Principal Component Analysis to extract transformed and informative features. These features are then used in the training of classification and regression models for machine state monitoring. Specifically, three classifiers (K-nearest neighbors, convolutional neural networks and support vector machines) and two regressors (support vector regression and neural network regression) were explored, in terms of their accuracy in machine state prediction. It is shown that the audio and vibration signals are sufficiently rich in information about the machine that 100% state classification accuracy could be accomplished. Data fusion was also explored, showing overall superior accuracy of data-driven regression models.

42 ENGINEERING↗
DOE OSTI2020

Smart Composite Pressure Vessels (SCPV) with Integrated Health Monitoring

The U.S. Department of Energy (DOE) is promoting and developing more energy efficient and environmentally friendly technologies that will enable America to use less petroleum. Hydrogen fuel cells – which directly convert the chemical energy in hydrogen to electricity with only water and heat as byproducts – are a very attractive solution that can enable this to happen. To date, DOE's efforts have culminated in commercial demonstration of on-board vehicular hydrogen storage systems that can allow for a driving range of greater than 300 miles. This requires storing 5 Kgs of hydrogen onboard a light vehicle. In order to store this quantity of hydrogen, the hydrogen gas needs to be stored in a composite overwrapped pressure vessel (COPV) at a very high internal pressure. The objective of the program was to demonstrate continuous and predictable health-monitoring of composite pressure vessels. A higher confidence in the operational safety of the vessels will lead to reduced burst factor of safety imposed by regulatory standards and hence will help reduce the structural wall thickness that drives the cost of the vessel. Highly optimized Type III (metal lined) and Type IV (polymer lined) COPVs that are manufactured using filament winding process have been designed and qualified for the above mentioned application. However, the main structural component of the COPVs is carbon fiber and the high cost of carbon fiber composite in a pressure vessel is a primary challenge in reducing the cost of gaseous hydrogen storage. Continuous and remote monitoring of structural health of the COPVs as well as optimization of the strength translation of carbon fibers have the potential to allow for reduced factor of safety, thereby reduced amount of carbon and associated cost of the vessel. In the current program, the project team including Steelhead Composites (SHC), University of Tennessee, Knoxville (UTK), Teijin Carbon America, Oak Ridge National Laboratory (ORNL) and LUNA designed, fabricated, and tested smart composite pressure vessels with integrated sensors. Iterative loops of design and testing using coupons, subscale STEB vessels and full size vessels proved that a new generation of high performance carbon fiber can be used for efficient design of Type 3 vessels for H2 storage. Novel analysis techniques were developed to predict the initiation and propagation of interlaminar damage inside the composite shell due to impact damage, a real threat in practical operation. Such an analysis scheme is typically not used in tank design but is an essential tool for health monitoring of composite vessels. Remote sensing of the key signatures of the tank’s operating parameters such as pressure, acceleration and humidity was demonstrated using a unique device that can wirelessly transmit and stream the data to a remote server. Fiber optic sensors were successfully integrated during fabrication of the tanks. These sensors provide a wealth of information regarding the structural health of the vessel when it is subsequently pressurized or subjected to impact damage. Excellent correlation was demonstrated between the fiber optic sensor and mechanical strain gage data, and between the measurements and analytical predictions.

08 HYDROGEN↗
DOE OSTI2023

Survey of Aging and Monitoring Concerns for Cables and Splices Due to Cable Repair and Replacement

The purpose of this report is to survey aging and monitoring concerns for electrical cable splices in nuclear power plants (NPPs) in long term operation. As portions of existing electrical cable runs in nuclear are replaced over time due to localized events, the total number of splices in NPPs is expected to increase. Relative to cables, the body of knowledge regarding aging of splices and splices in combination with aging cables in nuclear service environments in long-term operations is low. A few reports have considered the aging of cable system components other than cables (Jacobus 1990; Nelson 1998; Villaran and Lofaro 2002), but the nuclear industry has two decades of operating experience since these were published to further enlighten this issue. Herein we discuss electrical cables and splices commonly found in U.S. nuclear power plants, their qualification in safety-related application, and methods for monitoring their health condition. Common environmental stresses that can give rise to cable and splice failure are discussed. The Nuclear Regulatory Commission (NRC) Licensee Event Reports (LER) database was used to identify documented issues of cable and splice failure. The trend in the resultant data over time is considered to see if failures are increasing as plants age. Observations and conclusions of this work include: 1. Cables and splices are highly reliable components. Occurrence rates for events of interest were low and nearly constant over the last 20 years. 2. Common-cause failure for evaluated cable events of interest was observed to primarily be associated with loose connections, which may manifest associated with workmanship issues, thermal cycling, and/or vibration. 3. Replacement of cables is more common than repair, leading to an increase in proportion of new generation cables in the plant over time. 4. Splices on degraded cables have been observed to be problematic. Due to aging NPP infrastructure, including electrical cables, it is expected that such issues will continue to increase. 5. Condition monitoring approaches, while shown to be fruitful for cables, have been shown to be insensitive to degradation of splice sleeves, which are critical to the continued performance of splices. Additional condition monitoring (CM) work is needed to evaluate methods which are sensitive to the degradation of splice components. 6. Extended Material Degradation Assessment (EMDA) knowledge gaps for electrical cables (Bernstein et al. 2014) have not been investigated for splices but may represent similar concerns such as for the accelerated aging process historically used in environmental qualification.

42 ENGINEERING↗
DOE OSTI2025

Feasibility Assessment of Using Electrical Impedance Tomography for Damage Localization in Graphite Microreactor Components

Microreactors have great potential to decrease capital costs and construction timelines, reducing the barriers to implementing advanced nuclear reactor technologies. However, the lower power output of these microreactors introduces economic challenges if the operation and maintenance costs cannot be reduced sufficiently. Many microreactor concepts use graphite materials for in-core moderator and structural purposes, which will require periodic inspection or, ideally, in situ structural health monitoring. This work describes an initial evaluation of the feasibility of leveraging graphite’s semiconducting properties to perform electrical impedance tomography (EIT) for defect localization. First, a study was performed to identify the best methods for bonding electrical contacts to minimize the effects of contact resistance that interfere with impedance measurements of the graphite. After determining the best bonding approach, electrodes were attached to multiple graphite components with varying geometries (e.g., simple block and more representative microreactor hexagonal block). In parallel, finite element analysis approaches were developed and implemented to analyze the impact of defects and contact resistances and to inform an iterative inverse model for reconstructing the conductivity distribution. The results of this study show that defect localization in graphite components is possible using EIT if a sufficient number of electrodes (to improve spatial resolution) can be bonded using a technique with very low contact resistance and those contact resistances remain stable during reactor operation. If the reactor core and vessel design do not allow electrodes to be bonded during reactor operation, then it may be possible to detach/reattach electrodes between reactor operation and outages if a suitable mechanical connection that offers repeatable contact resistance can be identified. Alternatively, future work could focus on identifying contacts that can survive the harsh reactor operating environment so that contacts do not need to be removed.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗