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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 OSTI2022

Integrated Risk-Informed Condition Based Maintenance Capability and Automated Platform: Technical Report 3

This project is a collaborative research effort between PKMJ Technical Services LLC, Idaho National Laboratory, and Public Service Enterprise Group (PSEG) Nuclear, LLC. The collaboration, led by PKMJ Technical Services LLC, is part of the industry Funding Opportunity Announcement (FOA) award under Advanced Nuclear Technology Development FOA #DE-FOA-0001817. The pilot demonstration focuses on the Circulating Water System (CWS), an important non-safety-related system that impacts the power generation capability of the plant site. Achieving riskinformed condition-based Predictive Maintenance (PdM) on the CWS will result in significant economic benefits, and the developed methodologies can also be applied to other plant systems. This approach supports an industry goal of ensuring that nuclear power generation remains a viable, economically competitive option in the energy market. Operation and Maintenance (O&M) costs include labor-intensive Preventive Maintenance (PM) programs that involve manually performed inspection, calibration, testing, and maintenance of plant assets at periodic frequencies as well as time-based replacement of assets, irrespective of condition. This project offers an alternative by focusing on riskinformed condition-based maintenance to reduce O&M costs while still maintaining plant health and safety. This report summarizes the progress made toward achieving a risk-informed condition-based maintenance approach. The research and development (R&D) activities presented in this report are associated with development of a nuclear digital platform application, integration of fault signature models, and automated work management processes. The fault signatures and Machine Learning (ML) models are key components in predictive analytics and are heavily leveraged to improve the insights received by existing plant process data sources. Availability of the analysis results within a centralized digital platform enhances efficiency by enabling automation of activities otherwise performed manually. Personnel are presented with enhanced information that can be used to evaluate plant status and risks. Utilizing the enhancements to data analytics supports automated responses, (i.e. issuance of work orders) to address developing equipment faults and thus preventing forced, unplanned shutdowns of components or systems. The R&D activities described within this report lay the foundation for developing and demonstrating a digital automated platform to centralize the implementation of condition monitoring and response to equipment faults. The digital automated platform is cloud-based and designed to enable improved efficiency of plant processes. The digital platform includes content related to maintenance optimization, fault signature analysis, and plant records, which can all be used to support efficiencies when located within a centralized digital platform. These efficiencies could be further enhanced when deployed through industry-wide deployment of the technology to improve insights and processes based upon economies of scale.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Reinforcement learning for adaptive maintenance policy optimization under imperfect knowledge of the system degradation model and partial observability of system states

Maintenance policy optimization usually is faced with challenges that arise from an imperfect knowledge of system degradation models and from the partial observability of system degradation states. Here, this paper proposes a reinforcement learning method to address these two challenges for a class of maintenance problems with Markov degradation processes. The reinforcement learning approach consists of a learning component and a planning component. Using sequentially collected observations, at each step of decision-making the learning component improves the knowledge of system degradation in terms of the probability distributions of the transition rates based on sequential Bayesian inference. Using the updated transition rates, at each step of decision-making the maintenance policy optimization problem is then formulated as a partially observable Markov decision problem, and the planning component computes the optimal maintenance policy that maximizes the expected cumulative reward. The proposed method is illustrated using a numerical example with repair and inspection maintenance actions. The result shows that as more observations are collected, the learning component progressively learns the true system degradation process, and the planning component adjusts the optimal maintenance policy accordingly as well, which leads to increased reward.

42 ENGINEERING↗
DOE OSTI2026

Valuing Maintenance Strategies for Fusion Plants as Part of a Future Electricity Grid

Scheduled maintenance is likely to be lengthy and therefore consequential for the economics of fusion power plants. The maintenance strategy that maximizes the economic value of a plant depends on internal factors such as the cost and durability of the replaceable components, the frequency and duration of the maintenance blocks, and the external factors of the electricity system in which the plant operates. Here, this paper examines the value of fusion power plants with various maintenance properties in a decarbonized United States Eastern Interconnection circa 2050. Seasonal variations in electricity supply and demand mean that certain times of year, particularly spring to early summer, are best for scheduled maintenance. Seasonality has two important consequences. First, the value of a plant can be 15% higher than what one would naively expect if value were directly proportional to its availability. Second, in some cases, replacing fractions of a component in shorter maintenance blocks spread over multiple years is better than replacing it all at once during a longer outage, even through the overall availability of the plant is lower in the former scenario.

power plant, maintenance, seasonality, electricity↗
DOE OSTI2019

Identification of Balance of Plant Asset and Wireless Instrumentation to Enable Predictive Maintenance

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 its condition. This has resulted in a labor-centric business model to achieve high capacity factors. To achieve 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 transition from a labor-centric business model to a technology-centric business model. 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.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
NASA NTRS1998

Implementing a Reliability Centered Maintenance Program at NASA's Kennedy Space Center

Maintenance practices have long focused on time based "preventive maintenance" techniques. Components were changed out and parts replaced based on how long they had been in place instead of what condition they were in. A reliability centered maintenance (RCM) program seeks to offer equal or greater reliability at decreased cost by insuring only applicable, effective maintenance is performed and by in large part replacing time based maintenance with condition based maintenance. A significant portion of this program involved introducing non-intrusive technologies, such as vibration analysis, oil analysis and I/R cameras, to an existing labor force and management team.

DIAGNOSTIC EQUIPMENT↗
DOE OSTI2019

A Balanced Approach to Molded Case Circuit Breaker Maintenance

Abstract – NFPA 70E mandates that "overcurrent devices shall be maintained in accordance with the manufacturer's instructions or industry consensus standards". At our laboratory this mandate is law, because 10 CFR 851 requires adherence to NFPA 70 and 70E. This begs the question, exactly what are those manufacturer's instructions, and what do the industry consensus standards require? In particular with Molded Case Circuit Breakers (MCCB's), how does one meet these requirements and still apply a balanced approach in a maintenance program when the facilities range from brand new construction to over fifty years old, and where circuit breakers exist that have been made by virtually every major manufacturer? This paper examines the instructions given by the various manufacturers, and examines the standards that exist, along with major guides and white paper recommendations. Both the consistencies and the inconsistencies are examined, recommendations are compared, and a general consensus of recommendations emerges. The various maintenance particulars are examined, from cycling of breakers and thermography to inverse thermal and instantaneous primary injection trip testing. The results of an FMEA (Failure Modes and Effects Analysis) was conducted at our facility; the results of that FMEA and the recommendations of that FMEA for maintenance of MCCB’s are presented. In this paper, we have examined the recommendations of manufacturers, standards, and guides that provide the guidelines for maintenance of molded case circuit breakers. Although many conflicts exist, a consensus of nearly universal recommendations emerges. A balanced approach to maintenance that provides the maximum safety benefit within the bounds of economic feasibility can be developed. We provide a condensation of the existing literature with references, a visual summary of that literature and propose a recommended maintenance approach.

42 ENGINEERING↗
DOE OSTI2025

Enhanced Power Grid Maintenance Planning and Quantum-Inspired Combinatorial Prospects

Efficient and reliable scheduling of maintenance for power generation and transmission infrastructure is essential for minimizing operational costs and ensuring grid stability. This paper introduces an integrated optimization framework for coordinated maintenance scheduling of generators and transmission lines under resource and reliability constraints. The model minimizes a composite cost function including maintenance and generation costs, as well as penalties for delayed maintenance, while satisfying N−1 security constraints, operational limits, and crew availability. Case studies on the IEEE 300-bus test system demonstrate the effectiveness of the proposed approach in producing feasible and cost-effective maintenance schedules. To address scalability and combinatorial complexity, the model is mapped into a Quadratic Unconstrained Binary Optimization (QUBO) problem, enabling exploration of solution approaches based on Quantum Imaginary Time Evolution (QITE). While the QUBO reformulation provides a foundation for future quantum-inspired optimization, this study focuses primarily on the development and demonstration of the classical optimization framework and illustrates the potential applicability of QITE in large-scale maintenance scheduling.

Chen, Yang [ORNL] (ORCID:0000000271693874)↗
DOE OSTI2026

Facilitating Data Collection of Maintenance Events to Populate the Hydrogen Component Reliability Database (HyCReD)

The Hydrogen Component Reliability Database (HyCReD) is a collaborative project between the National Renewable Energy Laboratory, the University of Maryland, and hydrogen stakeholders to improve safety and reliability for hydrogen facilities by implementing component reliability data taxonomies that support hydrogen infrastructure failure rate analysis. The project aims to quantify failure rates of hydrogen components through high-quality data collection and analysis on root causes and maintenance needed. HyCReD provides a common database for cataloging hydrogen component failures which exists for reliability research in many other mature industries [2]. The database fills a gap for the hydrogen community by providing a scientifically rigorous approach to quantitative risk assessment (QRA), prognostic health management (PHM), and reliability-centered maintenance (RCM) analysis. High level results will be aggregated and anonymized to protect company sensitive information; detailed results will be used to help address issues of hydrogen components. These advanced analytics will support accelerated deployment of hydrogen infrastructure by enabling better: design and safety of projects (safety codes and standards development), infrastructure reliability and cost (component failure rates, maintenance protocols), and component R&D needs (robust supply chain). A key to a successful HyCReD implementation is facilitating the ease of reporting and data quality in the database that can be used for analysis. Maintenance data was a previously identified gap in initial efforts to populate and validate the database taxonomies [3]. Collection of maintenance data will be instrumental in identifying failure modes and rates, identifying incipient component failures or reduced performance, cataloging best practices for maintenance routines and methods for prognostic health management, and quantifying the risk and effect of different failure modes. Several key priorities are identified for streamlined data collection to achieve quality and detailed failure data: Applicability, Ease of Use, Accessibility, and Information Security. The HyCReD team has now begun deployment of the database to several companies and groups that have signed non-disclosure agreements to facilitate the data collection of failures in industry hydrogen refueling station infrastructure. This paper will provide an update into the process of HyCReD deployment including the development of a coding guide for facility personnel to reference and ensure data quality and consistency from one station to another as well as implementation of contextually dependent data fields of system taxonomy and formatted entries to provide ease of use. The goal is to communicate the lessons learned from the roll-out to technicians and engineers in the field, and the addition of need for high level of security to protect all stakeholders.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
NASA NTRS1978

Test evaluation of space station ECLSS maintenance concepts

The Space Station Prototype (SSP) Environmental Control and Life Support System (ECLSS) hardware was designed and built to be maintainable by the flight crew. To achieve this goal, subsystems were designed for ease of component removal and installation, which included accessibility to component fasteners and connectors, adequate tool clearance, minimum fluid loss during changeout, positive capture of loose parts during changeout, replacement by one crewman, and protection of adjacent parts during maintenance. During testing of this hardware, many day-to-day problems arose which allowed the evaluation of the maintenance concepts under actual maintenance conditions. This paper briefly discusses the maintenance objectives of the hardware design. Specific maintenance designs and their test evaluations are discussed. A removable cartridge valve concept for liquid line components and threaded mechanical fittings and V-band couplings for gaseous line components are critiqued. Other maintenance devices are also evaluated.

Reysa, R. P.↗
NASA NTRS1978

Study of turboprop systems reliability and maintenance costs

The overall reliability and maintenance costs (R&MC's) of past and current turboprop systems were examined. Maintenance cost drivers were found to be scheduled overhaul (40%), lack of modularity particularly in the propeller and reduction gearbox, and lack of inherent durability (reliability) of some parts. Comparisons were made between the 501-D13/54H60 turboprop system and the widely used JT8D turbofan. It was found that the total maintenance cost per flight hour of the turboprop was 75% higher than that of the JT8D turbofan. Part of this difference was due to propeller and gearbox costs being higher than those of the fan and reverser, but most of the difference was in the engine core where the older technology turboprop core maintenance costs were nearly 70 percent higher than for the turbofan. The estimated maintenance cost of both the advanced turboprop and advanced turbofan were less than the JT8D. The conclusion was that an advanced turboprop and an advanced turbofan, using similar cores, will have very competitive maintenance costs per flight hour.

Source record↗
NASA NTRS1980

Modeling a maintenance simulation of the geosynchronous platform

A modeling technique used to conduct a simulation study comparing various maintenance routines for a space platform is dicussed. A system model is described and illustrated, the basic concepts of a simulation pass are detailed, and sections on failures and maintenance are included. The operation of the system across time is best modeled by a discrete event approach with two basic events - failure and maintenance of the system. Each overall simulation run consists of introducing a particular model of the physical system, together with a maintenance policy, demand function, and mission lifetime. The system is then run through many passes, each pass corresponding to one mission and the model is re-initialized before each pass. Statistics are compiled at the end of each pass and after the last pass a report is printed. Items of interest typically include the time to first maintenance, total number of maintenance trips for each pass, average capability of the system, etc.

Kleiner, A. F., Jr.↗
NASA NTRS1982

Innovation for maintenance technology improvements

A group of 34 submitted entries (32 papers and 2 abstracts) from the 33rd meeting of the Mechanical Failures Prevention Group whose subject was maintenance technology improvement through innovation. Areas of special emphasis included maintenance concepts, maintenance analysis systems, improved maintenance processes, innovative maintenance diagnostics and maintenance indicators, and technology improvements for power plant applications.

Shives, T. R.↗
NASA NTRS1999

Spacecraft Software Maintenance: An Effective Approach to Reducing Costs and Increasing Science Return

Flight software is a mission critical element of spacecraft functionality and performance. When ground operations personnel interface to a spacecraft, they are typically dealing almost entirely with the capabilities of onboard software. This software, even more than critical ground/flight communications systems, is expected to perform perfectly during all phases of spacecraft life. Due to the fact that it can be reprogrammed on-orbit to accommodate degradations or failures in flight hardware, new insights into spacecraft characteristics, new control options which permit enhanced science options, etc., the on- orbit flight software maintenance team is usually significantly responsible for the long term success of a science mission. Failure of flight software to perform as needed can result in very expensive operations work-around costs and lost science opportunities. There are three basic approaches to maintaining spacecraft software--namely using the original developers, using the mission operations personnel, or assembling a center of excellence for multi-spacecraft software maintenance. Not planning properly for flight software maintenance can lead to unnecessarily high on-orbit costs and/or unacceptably long delays, or errors, in patch installations. A common approach for flight software maintenance is to access the original development staff. The argument for utilizing the development staff is that the people who developed the software will be the best people to modify the software on-orbit. However, it can quickly becomes a challenge to obtain the services of these key people. They may no longer be available to the organization. They may have a more urgent job to perform, quite likely on another project under different project management. If they havn't worked on the software for a long time, they may need precious time for refamiliarization to the software, testbeds and tools. Further, a lack of insight into issues related to flight software in its on-orbit environment, may find the developer unprepared for the challenges. The second approach is to train a member of the flight operations team to maintain the spacecraft software. This can prove to be a costly and inflexible solution. The person assigned to this duty may not have enough work to do during a problem free period and may have too much to do when a problem arises. If the person is a talented software engineer, he/she may not enjoy the limited software opportunities available in this position; and may eventually leave for newer technology computer science opportunities. Training replacement flight software personnel can be a difficult and lengthy process. The third approach is to assemble a center of excellence for on-orbit spacecraft software maintenance. Personnel in this specialty center can be managed to support flight software of multiple missions at once. The variety of challenges among a set of on-orbit missions, can result in a dedicated, talented staff which is fully trained and available to support each mission's needs. Such staff are not software developers but are rather spacecraft software systems engineers. The cost to any one mission is extremely low because the software staff works and charges, minimally on missions with no current operations issues; and their professional insight into on-orbit software troubleshooting and maintenance methods ensures low risk, effective and minimal-cost solutions to on-orbit issues.

Shell, Elaine M.↗
NASA NTRS1998

Automated System Checkout to Support Predictive Maintenance for the Reusable Launch Vehicle

The Propulsion Checkout and Control System (PCCS) is a predictive maintenance software system. The real-time checkout procedures and diagnostics are designed to detect components that need maintenance based on their condition, rather than using more conventional approaches such as scheduled or reliability centered maintenance. Predictive maintenance can reduce turn-around time and cost and increase safety as compared to conventional maintenance approaches. Real-time sensor validation, limit checking, statistical anomaly detection, and failure prediction based on simulation models are employed. Multi-signal models, useful for testability analysis during system design, are used during the operational phase to detect and isolate degraded or failed components. The TEAMS-RT real-time diagnostic engine was developed to utilize the multi-signal models by Qualtech Systems, Inc. Capability of predicting the maintenance condition was successfully demonstrated with a variety of data, from simulation to actual operation on the Integrated Propulsion Technology Demonstrator (IPTD) at Marshall Space Flight Center (MSFC). Playback of IPTD valve actuations for feature recognition updates identified an otherwise undetectable Main Propulsion System 12 inch prevalve degradation. The algorithms were loaded into the Propulsion Checkout and Control System for further development and are the first known application of predictive Integrated Vehicle Health Management to an operational cryogenic testbed. The software performed successfully in real-time, meeting the required performance goal of 1 second cycle time.

Patterson-Hine, Ann↗
NASA NTRS2002

Unsafe acts and unsafe outcomes in aircraft maintenance

Road safety studies using the Driver Behaviour Questionnaire (DBQ) have provided support for a three-way distinction between violations, skill-based errors and mistakes, and have indicated that a tendency to commit driving violations is associated with an increased risk of accident involvement. The aims of this study were to examine whether the three-way distinction of unsafe acts is applicable in the context of aircraft maintenance, and whether involvement in maintenance safety occurrences can be predicted on the basis of self-reported unsafe acts. A Maintenance Behaviour Questionnaire (MBQ) was developed to explore patterns of unsafe acts committed by aircraft maintenance mechanics. The MBQ was completed anonymously by over 1300 Australian aviation mechanics, who also provided information on their involvement in workplace accidents and incidents. Four factors were identified: routine violations, skill-based errors, mistakes and exceptional violations. Violations and mistakes were related significantly to the occurrence of incidents that jeopardized the quality of aircraft maintenance, but were not related to workplace injuries. Skill-based errors, while not related to work quality incidents, were related to workplace injuries. The results are consistent with the three-way typology of unsafe acts described by Reason et al. (1990) and with the DBQ research indicating an association between self-reported violations and accidents. The current findings suggest that interventions addressed at maintenance quality incidents should take into account the role of violations and mistakes, and the factors that promote them. In contrast, interventions directed at reducing workplace injury are likely to require a focus on skill-based errors.

Maintenance/manpower/methods↗
NASA NTRS2001

On-Orbit Maintenance Operations Strategy for the International Space Station - Concept and Implementation

The International Space Station (ISS) has an operational mission and profile that makes it a Logistics and Maintenance (L&M) support challenge different from previous programs. It is permanently manned, assembled on orbit, and multi-national. With this technical and operational challenge, a unique approach is needed to support the hardware and crew. The key is the integration of on-orbit and ground analysis, supply, maintenance, and crew training into a coherent functional process that supports ISS goals and objectives. To integrate all the necessary aspects of hardware and personnel to support on-orbit maintenance, a myriad of products and processes must be created and coordinated, such that the right resources are in the right place at the right time to ensure continued ISS functionality. This paper will familiarize the audience with ISS On-Orbit Maintenance (OOM) concepts and capabilities for different maintenance tasks and discuss some of the logic behind their selection. It will also identify the operational maintenance support responsibility split between the U.S. and the various International Partners (IPs).

Patterson, Linda P.↗
DOE OSTI2017

Compressed Natural Gas Vehicle Maintenance Facility Modification Handbook

To ensure the safety of personnel and facilities, vehicle maintenance facilities are required by law and by guidelines of the National Fire Protection Association (NFPA) and the International Fire Code (IFC) to exhibit certain design features. They are also required to be fitted with certain fire protection equipment and devices because of the potential for fire or explosion in the event of fuel leakage or spills. All fuels have an explosion or fire potential if specific conditions are present. The hazard presented by liquid fuels, such as gasoline and diesel, results from the spillage of these liquids and subsequent ignition of vapors, causing a fire or explosion. Facilities that maintain liquid-fueled vehicles and implement appropriate safety measures are protected with ventilation systems designed to capture liquid fuel vapors at or near floor level. To minimize the potential for ignition in the event of a spill, receptacles, electrical fixtures, and hot-work operations, such as welding, are located outside of these areas. Compressed natural gas (CNG) is composed of methane with slight amounts of heavier simple hydrocarbons. Maintenance facilities that maintain CNG vehicles indoors must be protected against fire and explosion. However, the means of ensuring safety are different from those employed for liquid fuels because of the gaseous nature of methane and the fact that it is lighter than air. Because CNG is lighter than air, a release will rise to the ceiling of the maintenance facility and quickly dissipate rather than remaining at or near floor level like liquid fuel vapors. Although some of the means of protection for CNG vehicle maintenance facilities are similar to those used for liquid-fueled vehicles (ventilation and elimination of ignition sources), the types and placement of the protection equipment are different because of the behavior of the different fuels. The nature of gaseous methane may also require additional safeguards, such as combustible gas detectors and control systems, or specialized space heating, which are not needed in facilities servicing liquid-fuel vehicles. This handbook covers maintenance facilities that service CNG-fueled vehicles. Although similar requirements are mandated for liquefied natural gas (LNG) or liquefied petroleum gas (LPG) fueled vehicles, LNG and LPG are not covered in this handbook.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2025

A survey on degradation modeling, prognosis, and prognostics-driven maintenance in wind energy systems

Wind energy generation proliferated over the past decades, introducing unique challenges and opportunities for failure prediction, operation and maintenance. Decision-makers are continuously looking into new methods to infer failure mechanisms and behaviors of wind turbine components to detect and intervene in the failures before they happen. Evidently, degradation modeling and prognosis become engaging topics for researchers and practitioners to prevent catastrophic failures. Prognostics-driven approaches predict the time of failure for the components (e.g., predicting remaining useful life), which provides significant insights for scheduling of operations and maintenance activities. Integrating these prognostics-driven insights into wind farm operations and maintenance presents a substantial challenge, demanding careful consideration of numerous factors such as accessibility, crew routing, and spare part logistics. This study provides state-of-the-art review for degradation modeling, prognosis, and prognostics-driven maintenance techniques for wind energy systems. The discussed techniques align with the United Nations' sustainable development goals, in particular Goal 7 (Affordable and Clean Energy), by enhancing effectiveness and sustainability of wind energy operations. This work also showcases open research questions related to degradation modeling, prognosis, and prognostics-driven maintenance.

Altinpulluk, Nur Banu↗