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NASA NTRS1994

Operations and support cost modeling of conceptual space vehicles

The University of Dayton is pleased to submit this annual report to the National Aeronautics and Space Administration (NASA) Langley Research Center which documents the development of an operations and support (O&S) cost model as part of a larger life cycle cost (LCC) structure. It is intended for use during the conceptual design of new launch vehicles and spacecraft. This research is being conducted under NASA Research Grant NAG-1-1327. This research effort changes the focus from that of the first two years in which a reliability and maintainability model was developed to the initial development of an operations and support life cycle cost model. Cost categories were initially patterned after NASA's three axis work breakdown structure consisting of a configuration axis (vehicle), a function axis, and a cost axis. A revised cost element structure (CES), which is currently under study by NASA, was used to established the basic cost elements used in the model. While the focus of the effort was on operations and maintenance costs and other recurring costs, the computerized model allowed for other cost categories such as RDT&E and production costs to be addressed. Secondary tasks performed concurrent with the development of the costing model included support and upgrades to the reliability and maintainability (R&M) model. The primary result of the current research has been a methodology and a computer implementation of the methodology to provide for timely operations and support cost analysis during the conceptual design activities.

Ebeling, Charles↗

DOE OSTI2010

Notional Examples and Benchmark Aspects of a Resilient Control System

Digital control system technology has pervaded most industries, leading to improvements in the efficiency and reliability of the associated operations. However, the ease of distributing and connecting related control systems for the purposes of increasing performance has resulted in interdependencies that can lead to unexpected conditions. Even with less complex designs, operators and engineers alike are often left with competing goals that are difficult to resolve. A fundamental reason for this dichotomy is that responsibilities lie with different disciplines, and operations are hosted on separate control systems. In addition, with the rising awareness of cyber security and diverse human interactions with control systems, an understanding of human actions from a malicious and benevolent standpoint is necessary. Resilience considers the multiple facets of requirements that drive the performance of control systems in a holistic fashion, whether they are security or stability, stability or efficiency, human interactions or complex interdependencies. As will be shown by example, current research philosophies lack the depth or the focus on the control system application to satisfy these requirements, such as graceful degradation of hierarchical control while under cyber attack. A resilient control system promises to purposefully consider these diverse requirements, developing an adaptive capacity to complex events that can lead to failure of traditional control system designs.

47 OTHER INSTRUMENTATION↗

DOE OSTI2017

Developing reliable safeguards seals for application verification and removal by State operators

Once a geological repository has begun operations, the encapsulation and disposal of spent fuel will be performed as a continuous, industrial-scale series of processes, during which time safeguards seals will be applied to transportation casks before shipment from an encapsulation plant, and then verified and removed following receipt at the repository. These operations will occur approximately daily during several decades of Sweden's repository operation; however, requiring safeguards inspectors to perform the application, verification, and removal of every seal would be an onerous burden on International Atomic Energy Agency's (IAEA's) resources. Current IAEA practice includes allowing operators to either apply seals or remove them, but not both, so the daily task of either applying or verifying and removing would still require continuous presence of IAEA inspectors at one site at least. Of special importance is the inability to re-verify cask or canisters from which seals have been removed and the canisters emplaced underground. Successfully designing seals that can be applied, verified and removed by an operator with IAEA approval could impact more than repository shipments, but other applications as well, potentially reducing inspector burdens for a wide range of such duties.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2014

A Distributed Control System Prototyping Environment to Support Control Room Modernization

Operators of critical processes, such as nuclear power production, must contend with highly complex systems, procedures, and regulations. Developing human-machine interfaces (HMIs) that better support operators is a high priority for ensuring the safe and reliable operation of critical processes. Human factors engineering (HFE) provides a rich and mature set of tools for evaluating the performance of HMIs, however the set of tools for developing and designing HMIs is still in its infancy. Here we propose a rapid prototyping approach for integrating proposed HMIs into their native environments before a design is finalized. This approach allows researchers and developers to test design ideas and eliminate design flaws prior to fully developing the new system. We illustrate this approach with four prototype designs developed using Microsoft’s Windows Presentation Foundation (WPF). One example is integrated into a microworld environment to test the functionality of the design and identify the optimal level of automation for a new system in a nuclear power plant. The other three examples are integrated into a full-scale, glasstop digital simulator of a nuclear power plant. One example demonstrates the capabilities of next generation control concepts; another aims to expand the current state of the art; lastly, an HMI prototype was developed as a test platform for a new control system currently in development at U.S. nuclear power plants. WPF possesses several characteristics that make it well suited to HMI design. It provides a tremendous amount of flexibility, agility, robustness, and extensibility. Distributed control system (DCS) specific environments tend to focus on the safety and reliability requirements for real-world interfaces and consequently have less emphasis on providing functionality to support novel interaction paradigms. Because of WPF’s large user-base, Microsoft can provide an extremely mature tool. Within process control applications,WPF is platform independent and can communicate with popular full-scope process control simulator vendor plant models and DCS platforms.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

Improving Coal-Fired Plant Performance Through Integrated Predictive and Condition-Based Monitoring Tools

The project demonstrated the ability to improve boiler performance and reliability through the integrated use of condition-based monitoring (CBM) and predictions of the impacts of coal quality on boiler operations at a full-scale coal-fired power plant. The advanced tool developed actively monitors and manages coal quality and overall boiler conditions that maximizes availability and maintains generating capacity while reducing cost. The tool is used to forecast and alert plant operators and engineers about poor boiler conditions which may occur as a result of incoming coal and/or current power plant operating conditions. The Combustion System Performance Indices (CSPI) and CoalTracker (CT) programs predicts fireside performance of the plant including slagging, fouling, erosion, slag flow, strength development (sintering/densification), and slag layer thickness based on the composition of delivered coal. CT program is tailored for each plant and is used to track the coal from the point of delivery to the burner. The most successful application of the CSPI-CT has been at plants where the coal composition is determined through the use of a full stream elemental analyzers based on prompt gamma neutron analysis (PGNAA). The CSPI-CT program information is used by coal procurement, coal mining and plant operations personnel to select and blend coal properties for the best plant performance.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2017

Review and Future Perspective of Central Receiver Design and Performance

Concentrating solar power (CSP) technology provides a commercial solar option to the utility-scale electricity market. CSP is unique in its ability to include low-cost thermal storage; thus, it can generate electricity when the sun is not available and dispatch electricity to meet varying load requirements. Within the suite of CSP technologies, the central receiver design represents the state-of-the-art technology, promising low cost, high performance, and dispatchable energy production. Current total capacity of central receiver plants worldwide is about 1.0 gigawatt (electric) with operating plants in Spain and the United States, as well as projects under construction in Asia, the Middle East, and North Africa. Central receiver technology has been under development since the 1950s, and a variety of central receiver designs have been explored. A distinguishing feature is the heat transfer medium. Central receiver designs exist that use dense fluids, gases, and solid particles in this role. Water/steam and molten salt receivers have been adopted in current commercial plants and are often coupled with a steam-Rankine power cycle with an operating temperature of less than 600 degrees C. Many new central receiver concepts, such as the volumetric air, supercritical carbon dioxide (sCO2), solid particle, and liquid-metal receiver designs, are under active research and development (R&D). New designs target operating temperatures generally higher than 700 degrees C-800 degrees C -- and even above 1000 degrees C -- so that higher-performance power cycles such as the sCO2-Brayton cycle or air-Brayton/steam-Rankine combined cycle can be used to promote greater overall system efficiency. Central receiver thermal storage provides dispatchability unavailable from variable-output renewables such as solar photovoltaic and wind power. Case study analysis of the California grid shows that there is a limit on the amount of non-dispatchable renewable generation that the grid can accommodate, beyond which overgeneration, spillage, and instability may occur. Energy storage may well become a necessity in some areas in order to maintain reliability. Next-generation central receiver technologies will have higher operating temperatures and additional features that allow higher-efficiency power generation and deliver other cost-performance advantages. The underlying innovations will come from areas such as multi-physics modeling, high-temperature materials, novel power cycles and heat exchanger designs, and collector field sensing and performance monitoring technologies. Technology innovation is expected to improve the cost and performance of central receiver designs. To deliver value as a generation and storage option, central receiver technology must also be supported by flexible and robust financial models and comprehensive energy and ancillary service markets justifying the capital-intensive investment. Progress in these areas will position CSP central receiver technology for future deployment.

14 SOLAR ENERGY↗

DOE OSTI2012

Dynamic Thermal Management for High-Performance Storage Systems

Thermal-aware design of disk drives is important because high temperatures can cause reliability problems. Dynamic Thermal Management (DTM) techniques have been proposed to operate the disk at the average case temperature, rather than at the worse case by modulating the activities to avoid thermal emergencies. The thermal emergencies can be caused by unexpected events, such as fan-breaks, increased inlet air temperature, etc. One of the DTM techniques is a delay-based approach that adjusts the disk seek activities, cooling down the disk drives. Even if such a DTM approach could overcome thermal emergencies without stopping disk activity, it suffers from long delays when servicing the requests. Thus, in this chapter, we investigate the possibility of using a multispeed disk-drive (called dynamic rotations per minute (DRPM)) that dynamically modulates the rotational speed of the platter for implementing the DTM technique. Using a detailed performance and thermal simulator of a storage system, we evaluate two possible DTM policies (- time-based and watermark-based) with a DRPM disk-drive and observe that dynamic RPM modulation is effective in avoiding thermal emergencies. However, we find that the time taken to transition between different rotational speeds of the disk is critical for the effectiveness of the DRPM based DTM techniques.

99 GENERAL AND MISCELLANEOUS↗

NASA NTRS2016

Applicability and Limitations of Reliability Allocation Methods

Reliability allocation process may be described as the process of assigning reliability requirements to individual components within a system to attain the specified system reliability. For large systems, the allocation process is often performed at different stages of system design. The allocation process often begins at the conceptual stage. As the system design develops, more information about components and the operating environment becomes available, different allocation methods can be considered. Reliability allocation methods are usually divided into two categories: weighting factors and optimal reliability allocation. When properly applied, these methods can produce reasonable approximations. Reliability allocation techniques have limitations and implied assumptions that need to be understood by system engineers. Applying reliability allocation techniques without understanding their limitations and assumptions can produce unrealistic results. This report addresses weighting factors, optimal reliability allocation techniques, and identifies the applicability and limitations of each reliability allocation technique.

Reliability allocation↗

NASA NTRS2011

Development of an Extreme High Temperature n-type Ohmic Contact to Silicon Carbide

We report on the initial demonstration of a tungsten-nickel (75:25 at. %) ohmic contact to silicon carbide (SiC) that performed for up to fifteen hours of heat treatment in argon at 1000 C. The transfer length method (TLM) test structure was used to evaluate the contacts. Samples showed consistent ohmic behavior with specific contact resistance values averaging 5 x 10-4 -cm2. The development of this contact metallization should allow silicon carbide devices to operate more reliably at the present maximum operating temperature of 600 C while potentially extending operations to 1000 C. Introduction Silicon Carbide (SiC) is widely recognized as one of the materials of choice for high temperature, harsh environment sensors and electronics due to its ability to survive and continue normal operation in such environments [1]. Sensors and electronics in SiC have been developed that are capable of operating at temperatures of 600 oC. However operating these devices at the upper reliability temperature threshold increases the potential for early degradation. Therefore, it is important to raise the reliability temperature ceiling higher, which would assure increased device reliability when operated at nominal temperature. There are also instances that require devices to operate and survive for prolonged periods of time above 600 oC [2, 3]. This is specifically needed in the area of hypersonic flight where robust sensors are needed to monitor vehicle performance at temperature greater than 1000 C, as well as for use in the thermomechanical characterization of high temperature materials (e.g. ceramic matrix composites). While SiC alone can withstand these temperatures, a major challenge is to develop reliable electrical contacts to the device itself in order to facilitate signal extraction

Evans, Laura J.↗

DOE OSTI2026

Energy Systems Integration Facility Stewardship Summary: Fiscal Year 2025

A summary of NLR's stewardship of the nationally unique Energy Systems Integration Facility (ESIF) highlighting performance metrics, capability upgrades, and examples of R&D impact. 2025 brought a national focus on energy and ESIF is meeting the moment. All eyes are on data centers and domestic manufacturing and bringing the benefits of artificial intelligence to power system planning and operations. In step with national priorities, ESIF is building out capabilities that advance secure, reliable, and affordable power. ESIF hosted 190 multidisciplinary research projects, 855 high-performance computer users, and collaborated with 81 partners from industry, academia, research, and federal agencies. These research projects resulted in an AI method for detecting high-impedance faults with 90% accuracy, a grid controls demonstration in Connecticut, power quality validation of CorePower's flagship inductor, and a cybersecurity assessment of potential rogue capabilities in digitally connected energy devices. Facility infrastructure improvements enhanced the thermal research network, the SCADA system, the cyber range, power hardware-in-the-loop testing, and more. With support from the U.S Department of Energy (DOE), the ESIF laboratories continue to deliver leading solutions for secure, reliable, and affordable power.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS2018

Assessing C2 Communications for UAS Traffic Management

The National Aeronautics and Space Administration's (NASA) Unmanned Aircraft Systems (UAS) Traffic Management (UTM) project works to develop tools and technologies essential for safely enabling civilian low-altitude UAS operations. Currently there is no established infrastructure to enable and safely manage the widespread use of low-altitude airspace and UAS operations, regardless of the type of UAS. The UTM technical challenge will develop comprehensive and validated airspace operations and integration requirements to safely enable large-scale persistent access to visual line of sight and autonomous beyond visual line of sight small UAS in low-altitude airspace. Within the UTM project, a number of communications technologies to support UTM command and control (C2) are under investigation. In particular, commercial networked cellular systems are being tested and assessed for their ability to meet the reliability, scalability, cybersecurity and redundancy required. NASA Glenn Research Center is studying some of the aspects of employing such networks for UTM C2 communications. This includes the development of a test platform for sensing and characterizing the airborne C2 communications environment at various altitudes and in various terrains and topologies, measuring such aspects as received signal strength and interference. System performance aspects such as latency in the link, handover performance, packet error loss rate, drop outs, coverage gaps and other aspects impacting UTM operation will also be assessed. In this paper we explore some of the C2 approaches being proposed and demonstrated in the UTM project, the reliability, availability and other general C2 performance requirements, and approaches to evaluating and analyzing UTM C2 links based on commercial cellular networks.

air traffic control↗

NASA NTRS2018

Assessing C2 Communications

aircraft communications↗

DOE OSTI2012

Combining Partial Redundancy and Checkpointing for HPC

Today's largest High Performance Computing (HPC) systems exceed one Petaflops (10^15 floating point operations per second) and exascale systems are projected within seven years. But reliability is becoming one of the major challenges faced by exascale computing. With billion-core parallelism, the mean time to failure is projected to be in the range of minutes or hours instead of days. Failures are becoming the norm rather than the exception during execution of HPC applications. Current fault tolerance techniques in HPC focus on reactive ways to mitigate faults, namely via checkpoint and restart (C/R). Apart from storage overheads, C/R-based fault recovery comes at an additional cost in terms of application performance because normal execution is disrupted when checkpoints are taken. Studies have shown that applications running at a large scale spend more than 50\% of their total time saving checkpoints, restarting and redoing lost work. Redundancy is another fault tolerance technique, which employs redundant processes performing the same task. If a process fails, a replica of it can take over its execution. Thus, redundant copies can decrease the overall failure rate. The downside of redundancy is that extra resources are required and there is an additional overhead on communication and synchronization. This work contributes a model and analyzes the benefit of C/R in coordination with redundancy at different degrees to minimize the total wallclock time and resources utilization of HPC applications. We further conduct experiments with an implementation of redundancy within the MPI layer on a cluster. Our experimental results confirm the benefit of dual and triple redundancy - but not for partial redundancy - and show a close fit to the model. At 80,000 processes, dual redundancy requires twice the number of processing resources for an application but allows two jobs of 128 hours wallclock time to finish within the time of just one job without redundancy. For narrow ranges of processor counts, partial redundancy results in the lowest time. Once the count exceeds 770, 000, triple redundancy has the lowest overall cost. Thus, redundancy allows one to trade-off additional resource requirements against wallclock time, which provides a tuning knob for users to adapt to resource availabilities.

Elliott, James↗

NASA NTRS1976

Initial operation of a solar heating and cooling system in a full-scale solar building test facility

The Solar Building Test Facility (SBTF) was constructed to advance the technology for heating and cooling of office buildings with solar energy. Its purposes are to (1) test system components which include high-performing collectors, (2) test the performance of a complete solar heating and cooling system, (3) investigate component interactions, and (4) investigate durability, maintenance and reliability of components. The SBTF consists of a 50,000 square foot office building modified to accept solar heated water for operation of an absorption air conditioner and for the baseboard heating system. A 12,666 square foot solar collector field with a 30,000 gallon storage tank provides the solar heated water. A description of the system and the collectors selected is printed along with the objectives, test approach, expected system performance, and some preliminary results.

Knoll, R. H.↗

DOE OSTI2014

Recent results and challenges in development of metallic Hall sensors for fusion reactors

Reliable and precise diagnostic of local magnetic field is crucial for successful operation of future thermonuclear fusion reactors based on magnetic confinement. Magnetic sensors at these devices will experience an extremely demanding operational environment with large radiation and thermal loads in combination with required long term, reliable, and service-free performance. Neither present day commercial nor laboratory measurement systems comply with these requirements. Metallic Hall sensors based on e.g. copper or bismuth could potentially satisfy these needs. We present the technology for manufacturing of such sensors and some initial results on characterization of their properties.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2021

Ensemble Learning, Prediction and Li-Ion Cell Charging Cycle Divergence

In recent years, the pervasive use of lithium ion (Li-ion) batteries in applications such as cell phones, laptop computers, electric vehicles, and grid energy storage systems has prompted the development of specialized battery management systems (BMS). The primary goal of a BMS is to maintain a reliable and safe battery power source while maximizing the calendar life and performance of the cells. To maintain safe operation, a BMS should be programmed to minimize degradation and prevent damage to a Li-ion cell, which can lead to thermal runaway. Cell damage can occur over time if a BMS is not properly configured to avoid overcharging and discharging. To prevent cell damage, efficient and accurate cell charging cycle characteristics algorithms must be employed. In this paper, computationally efficient and accurate ensemble learning algorithms capable of detecting Li-ion cell charging irregularities are described. Additionally, it is shown using machine and deep learning that it is possible to accurately and efficiently detect when a cell has experienced thermal and electrical stress due to cell overcharging by measuring charging cycle divergence.

25 ENERGY STORAGE↗

DOE OSTI2015

Microgrid Design Toolkit (MDT) Technical Documentation and Component Summaries

The Microgrid Design Toolkit (MDT) is a decision support software tool for microgrid designers to use during the microgrid design process. The models that support the two main capabilities in MDT are described. The first capability, the Microgrid Sizing Capability (MSC), is used to determine the size and composition of a new microgrid in the early stages of the design process. MSC is a mixed-integer linear program that is focused on developing a microgrid that is economically viable when connected to the grid. The second capability is focused on refining a microgrid design for operation in islanded mode. This second capability relies on two models: the Technology Management Optimization (TMO) model and Performance Reliability Model (PRM). TMO uses a genetic algorithm to create and refine a collection of candidate microgrid designs. It uses PRM, a simulation based reliability model, to assess the performance of these designs. TMO produces a collection of microgrid designs that perform well with respect to one or more performance metrics.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2015

PV Systems Reliability Final Technical Report.

The continued exponential growth of photovoltaic technologies paves a path to a solar-powered world, but requires continued progress toward low-cost, high-reliability, high-performance photovoltaic (PV) systems. High reliability is an essential element in achieving low-cost solar electricity by reducing operation and maintenance (O&M) costs and extending system lifetime and availability, but these attributes are difficult to verify at the time of installation. Utilities, financiers, homeowners, and planners are demanding this information in order to evaluate their financial risk as a prerequisite to large investments. Reliability research and development (R&D) is needed to build market confidence by improving product reliability and by improving predictions of system availability, O&M cost, and lifetime. This project is focused on understanding, predicting, and improving the reliability of PV systems. The two areas being pursued include PV arc-fault and ground fault issues, and inverter reliability.

14 SOLAR ENERGY↗