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NREL will provide technical assistance to help digitize best practice operations and maintenance (“O&M”) procedure guidelines utilizing the Illu platform for specific distributed solar-storage system configurations. NREL shall test Illu workflows in a real inspection environment for clarity of instruction and ease of documentation.
This report, in fulfillment of a U.S. Nuclear Regulatory Commission (NRC) license requirement, presents the results of long-term surveillance and maintenance activities conducted by the U.S. Department of Energy (DOE) Office of Legacy Management (LM) in 2024. These activities occurred at the 19 uranium mill tailings disposal sites established under Title I of the Uranium Mill Tailings Radiation Control Act (UMTRCA) and verify that the UMTRCA Title I disposal sites remain in compliance with license requirements and Long-Term Surveillance Plans (LTSPs). Individual chapters for each site are available on the LM public website at https://energy.gov/lm/sites/lm-sites.
The initial product specification' for the H12 Universal Cartridge Carrier (UUC) was released in October 1952 and is the twelfth piece of H-Gear (sequentially numbered) ever developed. It is the oldest piece of H-Gear currently in use. To gain perspective on the number of H-Gear since designed, the most currently developed and deployed H-Gear is the H1768, Inspection Stand. The UUC, (commonly referred to as just the "H12") has since been renamed to the H12 Adjustable Hand Truck. It was developed to support various maintenance operations for ordnance assembly and disassembly. This paper will provide evidence (where available) for the H12s current state of reliability, maintainability, and sustainability (RMA). Where documented evidence is not available, conclusions will be drawn based on its continued effective use over the past 67-years of service.
As compared to conventional nuclear reactors, microreactors have the potential to significantly reduce construction timelines and capital costs, decreasing the barriers for advanced nuclear reactor technologies. However, the lower power output of these microreactors (typically < 20 MWe) creates challenging economics if operation and maintenance costs cannot be sufficiently reduced. The compact size of these designs presents an opportunity for comprehensive in-situ structural health monitoring to provide real-time feedback in order to reduce operational costs associated with maintenance and downtime. Many microreactor concepts use graphite for both in-core neutron moderation and as a structural material, which has typically required some form of periodic and laborious inspection. This report provides a description and assessment of recent work with graphite to couple acoustic-based experimental measurements and characterization with machine learning models to mature structural health monitoring capabilities and generate benefits for the nuclear microreactor industry. With resilient embedded sensors in development in other programs funded by the US Department of Energy’s Office of Nuclear Energy and elsewhere, the work described herein builds upon previously funded efforts to mature non-destructive testing technology that relates measured vibrational signatures to structural changes, using a combination of new experimental measurements and machine learning processing. Building on past successful demonstrations of predictive workflows to identify structural changes in a hexagonal stainless steel test article with excellent acoustic propagation, we first performed baseline characterization on graphite samples with canonical geometries to ensure compatibility and confidence in the applied techniques for a material with distinctly different mechanical properties. In contrast to efforts in previous years, we worked exclusively with unidirectional vibration data that is more comparable to those expected from the existing embedded sensor technologies which are suitable for deployment in a reactor setting. Established acoustic and modern machine-learning-based characterization approaches were applied to the resulting datasets from these simple geometries. Both approaches were found to be highly capable of detecting even small geometric irregularities amongst nominally identical samples. As such, we then moved to testing these approaches for detection of artificial local stress perturbations introduced into a more complex geometry: a hexagonal block with drilled holes. A main outcome of this work is that a generalizable ML workflow can be used to detect and predict the characteristics of small artificial anomalies in a graphite component with a relevant geometry. While this work was performed using surficial vibration data, we expect the approach to be flexible and viable for other monitoring scenarios, such as those with different arrangements or types of sensor arrays. As compared to previously funded efforts, an existing ML workflow based on neural networks was enhanced through the addition of recently developed Fourier neural operators. As applied to previously collected and new vibration datasets, prediction accuracies of anomaly characterizations were greatly improved with minimal added computational cost. As trained on small durations of vibration data (tens of seconds) collected over a realistic number of locations, the model was able to reliably determine the presence of a subtle stress anomaly and begin to provide location estimates. Such an approach is likely to be viable for more relevant reactor damage scenarios for graphite components, such as progressive crack growth or creep.
Abstract. Pockets of open cells (POCs) have been shown to develop within closed-cell stratocumulus (StCu), and a large body of evidence suggests that the development of POCs result from changes in small-scale processes internal to the boundary layer rather than large-scale forcings. Precipitation is widely viewed as a key process important to POC development and maintenance. In this study, GOES-16 satellite observations are used in conjunction with MERRA-2 winds to track and compare the microphysical and environmental evolution of two populations of closed-cell StCu selected by visual inspection over the southeastern Pacific Ocean: one group that transitions to POCs and another comparison group (CLOSED) that does not. The high spatiotemporal resolution of the new GOES-16 data allows for a detailed examination of the temporal evolution of POCs in this region. We find that POCs tend to develop near the coast, last tens of hours, are larger than 104 km2, and often (88 % of cases) do not re-close before they exit the StCu deck. Most POCs are observed to form at night and tend to exit the StCu during the day when the StCu is contracting in area. Relative to the CLOSED trajectories, POCs have systematically larger effective radii, lower cloud drop number concentrations, a comparable conditional in-cloud liquid water path, and a higher frequency of more intense precipitation. Meanwhile, no systematic environmental differences other than boundary layer height are observed between POC and CLOSED trajectories. Interestingly, there are no differences in reanalysis aerosol optical depth between both sets of trajectories, which may lead one to the interpretation that differences in aerosol concentrations are not influencing POC development or resulting in a large number that re-close. However, this largely depends on the reanalysis treatment of aerosol–cloud interactions, and the product used in this study has no explicit handling of these important processes. These results support the consensus view regarding the importance of precipitation on the formation and maintenance of POCs and demonstrate the utility of modern geostationary remote sensing data in evaluating the POC life cycle.
Thermography technology is widely used to inspect thermal anomalies in building façade systems. Computer vision-based techniques provide opportunities to autonomously detect such heat anomalies to significantly improve the efficiency of decision-making for building envelope retrofitting and maintenance. Here, in this work, we propose a novel Capsule Network-based deep learning model – CapsLab – that detects and identifies thermal anomalies by semantic segmentation. CapsLab is built based on our proposed prediction-tuning capsule (PT-Capsule) layer. Different from a traditional capsule layer, which consists of part-whole transformation and capsule-routing process, the proposed layer is composed of a prediction and tuning process, which helps decreasing the number of model parameters significantly. While the applicability of traditional Capsule Networks (CapsNets) has been limited to simpler tasks and smaller datasets due to their scalability issue, we can leverage the lightweight of the proposed PT-Capsule layer, and apply it to the semantic segmentation task. In this work, we also employ our previously presented performance metric, referred to as the Anomaly Identification Metric (AIM) (Kakillioglua et al. 2021), to evaluate the segmentation outputs. Traditional performance metrics do not accurately reflect the true performance of the segmentation models in thermal anomaly identification due to the high subjectivity in the annotation process and higher overlap ratio sensitivity of the standard metrics. AIM, on the other hand, is robust to these drawbacks. Experimental results show, both qualitatively and quantitatively, that our proposed segmentation method can effectively segment the thermal anomalies. Specifically, our model provides 9.38% and 13.53% improvements over the baseline model – DeepLabV3+ – based on traditional mIoU score and the AIM score, respectively, while requiring less model parameters and less computation at the same time. In addition, the scores that the AIM metric generates better align with the scores provided by building performance experts.
This paper presents lessons learned regarding fabricating packaging systems from the perspective of a design authority (DA). Capturing and implementing lessons learned is critical for an organization to reduce systematic project risk and thereby promote the likelihood of project success. This paper defines the design authority as the organization responsible for technical design, resolving technical design issues, quality assurance program, and maintenance of the packaging system license. A package system is defined as the packaging, its contents, and auxiliary equipment. Packages are certified by the NRC under 10 CFR 71[1] for transportation by ground. The following lessons learned subjects are presented in the paper: quality assurance, interpretation of drawing dimensional requirements, execution of manufacturing processes, hardware dimensional inspection, and leakage rate testing. All discrepancies presented in this paper have been resolved as described in the appropriate final data package. All described package systems are in compliance with their Safety Analysis Report (SAR) and certificate of conformance requirements. The intent of this paper is to identify opportunities for improving the outcome of future projects and to mitigate fabrication challenges proactively. (authors)
This report documents the biennial postclosure site inspections conducted in June 2018 at the surface Corrective Action Unit (CA U) 417 at the Central Nevada Test Area, Nevada, Site. The UC-I, UC-3, and UC-4 sites are inspected every 2 years, in accordance with the Post-Closure Monitoring Plan provided in the CAU 417 Closure Report published in 2001. The requirements for postclosure monitoring have been modified over the years through negotiations with the Nevada Division of Environmental Protection (NDEP). Modifications were documented through three separate Records of Technical Change to the Closure Report, which were approved by NDEP in 2003, 2011, and 2015. The UC-1, UC-3, and UC-4 sites were all observed as being in good condition during the 2018 inspections. A few minor cracks on the UC-1 Central Mud Pit cover were repaired during the UC- I inspection. A concrete monument at the northeast corner of Mud Pit U3E at the UC-3 site had some damage near the top of the monument, but the damage has not impacted the functionality of the monument or survey pin on top of the monument. No issues were identified at the UC-4 site. No maintenance or additional repair activities are recommended at the UC-1, UC-3, and UC-4 sites.
The reliability, cost and performance of electrical connectors are a concern in all types of electrical systems, and demands on connectors used on photovoltaic (PV) systems include that connectors maintain electrical conductivity and physical strength, endure ultraviolet sunlight and high ambient temperature, and resist moisture and chemical intrusion over a very long (>25 year) performance period. Connector failures increase operation and maintenance (O&M) costs and reduce plant production, but connector failure can also cause safety and liability problems, which are of greater concern. This work results from a three-year collaboration between Sandia National Laboratories (SNL), the Electric Power Research Institute (EPRI), and the National Renewable Energy Laboratory (NREL) and funded by the U.S. Department of Energy (DOE) Solar Energy Technology Office (SETO) under Agreements #39035 and #38531 "Connector Reliability Across the US Solar Sector." a multi-pronged investigation of PV connector health across the US (see https://energy.sandia.gov/pvconnectors/). This report presents derivation of a Techno-Economic Analysis (TEA) that models failure modes and frequencies (how often failure occurs), estimates O&M costs and lost production associated with connector failures, and then calculates the effect that PV module connectors can have on Levelized Cost of Energy (LCOE). The model is informed with initial data from quantitative assessment of failure rates, root causes and mechanisms, in-situ diagnostics and data collection, lab-based forensics, and interviews with PV connector manufacturers and plant operators. SNL conducted site inspections at multiple utility-scale sites in different climates and subjected field samples of new, used, and degraded connectors to visual and electrical characterization. EPRI conducted metallurgical analysis of the pin and sleeve conductors to study failure-induced morphological and compositional changes. There is in general a shortage of statistically valid data, but data from PVROM database maintained by SNL was sufficient to ascertain failure rates and lost production as well as provide qualitative insight in its curated maintenance records. This report details the structure of the mathematical model but the sources of data to inform the model will continue to evolve. Analysis of a 100 MW PV plant is provided as an example of the use of the model, with results indicating that connectors are responsible for Annualized O&M Costs of $\$$71,933/year; Annualized Unit O&M Costs of $\$$0.72/kW/year; that a Reserve Account of $\$$187,220 should be available to fund repairs related to connectors; that connectors add $\$$1,494,004 to the Net Present Value of the O&M Costs (project life); and that O&M related to connectors adds about $\$$0.00088/kWh to the Levelized Cost of Energy. The impact of this model is to provide a tool to make the US solar sector more robust by quantifying and monetizing the reliability risks to utility-scale PV systems posed by poorly installed, mismatched and/or poorly designed and manufactured connectors. The TEA provides a model incorporating failure statistics, O&M cost data, and lost production into a single figure of merit, informing decisions and enabling practitioners to optimize cost and performance trade-offs. Stakeholders include connector manufacturers, system designers and equipment specifiers, standards bodies, installers and O&M providers, investors and insurance underwriters. This report supports continued growth of PV predicated on assurances that properly installed and maintained PV system connectors are safe and reliable. The project team is proposing future work including accelerated testing of connectors and expanding the approach taken here to other PV system components, such as TEA for rapid shut-down devices.
We overview a discrete event simulation of an arms control enterprise developed to familiarize individuals with the challenges of verification and monitoring at the enterprise level. We will review the design of the simulation applied to a notional country’s nuclear arms enterprise. This simulation models how these nuclear weapons move over their lifetime from deployment, storage, maintenance, and dismantlement. With this output information, we then characterize the “ground truth” of the enterprise. Next, based on these data, we built a sophisticated analysis engine designed to provide treaty monitoring and verification information to support partner country inspectors and their evaluation. This tool was designed to be used as a game, enabling teams to compete on developing the best inspection plan to determine if the host country is complying with the conceptual treaty developed for this effort.
To help SETO/DOE achieve its goals, the IBTS team proposed a project addressing system reliability by improving installation standards and quality management. The proposed approach was designed to help achieve measurable reductions in installation defect density and improvements in the performance of PV systems by optimizing design and installation of residential and commercial PV systems. This approach addressed the soft costs associated with installations and quality management. The project demonstrated improved system reliability and reduced PV system installation costs. The software developed improved operations, decreased risk, and increased the overall value of PV systems across their lifecycle. The project used several data collection methods, including extensive industry surveys, face-to-face high-level interviews at industry conferences, stakeholder teleconferences, and in-depth interviews conducted by IBTS staff. Results from the research found the industry needs a uniform assessment method for national providers to be more efficient; the software should support both code officials and installers; most industry stakeholders would find value in a centralized software system that allows them to collect, report, and review information on in-process and completed solar installations; and mobile solutions that bridge existing knowledge gaps with inspectors and integrate with existing methodologies (such as permitting software) are of great value. The software solution developed is web-based, allowing for national access, and is built on a Google Firebase platform that can handle significant users and data. It can be used onsite or remotely, allowing for code compliance to continue despite ongoing pandemic related delays or shutdowns for local economies. The information provided by the software tool allows users to uniformly assess a system for compliance and use that aggregated data to identify training topics or create internal process designed to improving issues and reducing occurrence. This solution has multiple benefits in managing quality at time of use and promoting an increase in future safety and quality through education. Perhaps most importantly, this software increases public safety by ensuring compliance of installed systems and allows for local AHJs to remotely engage specialized and qualified solar specific expertise for oversite of the installation in their jurisdictions. Data analysis provides the quality feedback loop identifying the root cause of failure and drives installation practices to improve through training and education, resulting in systems with higher performance, greater reliability, and reduced operations and maintenance costs. With the successful completion of this project, the industry can expect reduced soft costs and increased performance and safety and will ultimately benefit from longer performing systems that cost less to operate.
Photovoltaic (PV) connectors, which link modules in series and connect PV strings in parallel, have increasingly been recognized as a primary contributor to PV system failures and a source of numerous fire incidents. However, publicly available data on the rates and types of connector failures are scarce, primarily due to the proprietary nature of the information and the need for comprehensive analysis. This study represents the first large-scale investigation of harvested PV connectors, drawing from a dataset of 6276 connectors from residential rooftop solar systems across the United States. The outcome of this work is twofold: 1) we have established a rapid characterization method for large populations of harvested connectors, incorporating visual inspection, resistance measurements, and X-ray imaging; and 2) the analysis made possible by our rapid-processing method has revealed, for a population of connector models provided by a single rooftop installer, failure statistics and insights for various connector makes and models, installation practices, operating currents, and internal component displacements. This research identifies common failure modes that could be considered in future connector designs standards, and operations and maintenance practices, to ultimately improve the reliability of this vital component of PV infrastructure.
Scene change detection can be a tedious and time consuming process especially when concerning large geographical areas, and the process can be even more cumbersome when analyzing changes in an area over large spans of time. Developing a useful way to help analysts recognize at what points in time significant changes to a scene have occurred can allow them to better focus their efforts in characterizing events. Applications include: Facility monitoring, Construction chronology, Monitoring of vehicle/aircraft activity, Characterization of larger sequences of events. In large areas exceeding hundreds to thousands of square kilometers in size, it can be difficult localizing when scene changes have occurred. Analysts can spend hours going through imagery to try to identify new construction, monitor facility activities, monitor vehicle movement, etc. where the object of interest may only be a few square meters. Our goal is to help cut down this time by giving analysts change maps with hot spots of change, allowing them to focus on regions that have experienced actual change in time frames they're interested in. Additionally, by combining these change maps into layers within a data cube, analysts can examine the change maps from a temporal perspective, allowing events to be characterized over spans of time. By opening the data cube in an imaging software capable of separating the layers, we can analyze the change maps sequentially, allowing us to examine scene changes occurring over time. As an example, we examined overhead imagery from Planet Labs of what appears to be a parking lot on Fort Irwin over the course of a year using ENVI, a geospatial satellite imagery analysis software. Using ENVI, we generate a graph of changes over time, and notice a particular segment near the end of our analysis window where no changes are detected. Examination of the actual satellite imagery reveals that during this time span, the parking lot was empty. This could be due to facility shutdown for maintenance or upgrades, or possibly even total workforce/vehicle fleet movement. Information like this could help analysts better characterize events, as well as to help create clearer timelines in larger sequences of events. Workflow steps: - Collect multiple maps of the same AOI (Area of Interest) during a time span of interest; - Generate change maps from AOI maps; - Generate data cube from change maps. An analyst can use the data cube to help inspect an AOI for activities within a time span of interest. If an event of interest is discovered, the analyst can then refer to the maps corresponding to the appropriate dates and times in the data cube to see precisely what is transpiring. The biggest objective being worked on is improving the change detection methodology employed. We currently use PCA-EM (Principal Component Analysis with Expectation Maximization), but we are currently focusing on implementing IR-MAD (Iteratively Reweighted Multivariate Alteration Detection) to be used in conjunction with PCA-EM in an effort to decrease false positivity and noise in the change maps we generate.
A team of researchers from both the Air Force Institute and Technology and Los Alamos National Laboratory are developing a paint that contains a material called quantum dots which can optically measure deformation of a surface. Quantum dots are the same materials used in new QLED television displays; however, they can also be used for a multitude of sensing applications such as deformation. The researchers used a new method of applying an interfacial layer between the quantum dot paint and the surface under investigation to help adhesion in harsh environments. The primary motivation behind this research is to make both quality assurance and maintenance of aircraft easier for the warfighter. The researchers’ efforts started in 2019 and are continuing. The technology works by shining a light onto the surface of the paint and the dots will emit back a wavelength of light that relates to the amount of deformation the surface is going through. This has the promise to allow for real-time 2D surface measurements that is more affordable than other 2D surface measurement alternatives.
Photovoltaic (PV) connectors must maintain mechanical integrity for over 25 years while operating under UV exposure, elevated temperature, and mechanical loading. Connector degradation increases with electrical resistance, leading to energy losses, unplanned downtime, and higher operation and maintenance (O&M) costs and in severe cases, safety risks from overhearing or arcing. Connector related failures remain among the most frequent causes of disruption in utility-scale PV (UPV) systems, yet their lifetime economic impacts are poorly quantified. This work presents a techno-economic analysis (TEA) framework that links identified connector failure modes to system level energy losses and lifetime cost impacts using identified resistance measurements and failure rates from 6,2761 PV connectors inspected. Connector failures increase system level O&M costs, raising LCOE by roughly 5%. Downtime driven availability losses dominate economic impact. Resistance-driven I2R and IV-curve losses are secondary, but remain non-negligible. Thermal damage, bend-radius violations, and loose connections drive the majority of LCOE uplift Improving connector reliability through better installation quality, inspection, and design can meaningfully reduce lost energy, O&M costs, and LCOE.
The aim of this paper is to develop the concept and a prototype of an intelligent mobile robotic platform that is integrated with nondestructive evaluation (NDE) capabilities for autonomous live inspection and repair. In many industrial environments, such as the application of power plant boiler inspection, human inspectors often have to perform hazardous and challenging tasks. There is a significant chance of injury, considering the confined spaces and limited visibility of the inspection environment and hazards such as pressurization and improper water levels. In order to provide a solution to eliminate these dangers, the concept of a new robotic system was developed and prototyped that is capable of autonomously sweeping the region to be inspected. The robot design contains systematic integration of components from robotics, NDE, and artificial intelligence (AI). A magnetic track system is used to navigate over the vertical steel structures required for examination. While moving across the inspection area, the robot uses an NDE sensor to acquire data for inspection and repair. This paper presents a design of a portable NDE scanning system based on eddy current array probes, which can be customized and installed on various mobile robot platforms. Machine learning methods are applied for semantic segmentation that will simultaneously localize and recognize defects without the need of human intervention. Experiments were conducted that show the NDE and repair capabilities of the system. Improvements in human safety and structural damage prevention, as well as lowering the overall costs of maintenance, are possible through the implementation of this robotic NDE system.
In November 1990, an inspection visit was made to the residential lighting photovoltaic systems that had been installed approximately one year before in the rural communities of the Municipality of Pinotepa de Don Luis, in the State of Oaxaca. The main purpose of the visit was to evaluate the physical and operational status of these systems. The systems typically consist of a photovoltaic module with a capacity of 30 or 35 Watts, an automotive type battery, an indicator of the status of charge of the battery, 3 fluorescent lamps and the corresponding installation, including cables, connection or outlet box and switches. It can be seen that the systems are in good physical condition and do not show any signs of intentionally caused damage. However, the incidence of failures is higher than what had been expected; therefore the operational status of these systems is considered to be below a level that could be accepted, with a tendency to getting worse. The main problem that has been detected is the lack of automatic charge controllers. This problem has caused other important failures. Serious deficiencies were appreciated in the installations, which show evidence of the poor workmanship of the installers. The lack of system standardization is evident, both regarding the components and the installation. As a consequence, there are technical factors which indicate that the installed systems will keep deteriorating at a rate faster than normal, and will stop operating in a short time unless urgent preventive and corrective measures are taken. The attitude of the users with respect to the systems is generally positive. However, there are elements that make the correct operation and maintenance of these systems a very difficult task. The users did not receive any training regarding the best way to operate and take care of their systems, nor any other information in relation to their technical limitations.
Early defect detection in pipelines is critical across industries, particularly in the oil and gas sector, where failures result in significant maintenance costs and operational disruptions. Acoustic guided-wave techniques are widely used for nondestructive evaluation of pipeline defects due to their long-distance propagation capability. However, environmental variations, sensitivity limitations, and complex signal interpretation challenges limit the effectiveness of traditional signal processing approaches with guided-wave signals. Recent advances in deep learning methods have demonstrated remarkable success in solving complex real-world problems in many fields. In particular, deep-learning-based signal processing holds substantial promise to overcome limitations and challenges of conventional signal processing. This study presents a deep learning framework for pipeline inspection using acoustic guided-wave signals under temperature varying environments. The proposed framework employs a dual-path one-dimensional convolutional autoencoder that combines defect detection, localization, and temperature prediction functions. The proposed system utilizes multi-mode and broadband acoustic waves with an optimized number of sensors that provide high accuracy while retaining practical simplicity. Experimental validation is performed on a carbon steel pipe. The results indicate exceptional defect detection accuracy and precise defect localization with a mean absolute error of 66 mm. The proposed technique also predicts the effective average temperature of the pipe with a mean absolute error of 0.2°C. Comparative analysis shows superior performance of the proposed method over a traditional method previously developed by the authors' team. These results highlight the potential of integrating deep learning methods into guided-wave pipeline inspection systems to improve reliability under varying environmental conditions.