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NASA NTRS1998

TOPEX/Poseidon orbit maintenance for the first five years

The TOPEX/Poseidon orbit maintenance strategy was changed following launch to include the effects of observed unmodeled, and hence anomalous, along-track accelerations. The anomalous force causes the semi-major axis, a, to either increase (called "boost") or decrease ("deboost" or "decay") depending on the satellite attitude and solar array pitch angle offset. Although this force is the most uncertain parameter in ground track prediction, it has been used as a passive technique for orbit maintenance, thereby reducing the number of propulsive maneuvers, enhancing maneuver spacing, and to place maneuvers at convenient times. This passive technique was first demonstrated in May 1993. The TOPEX/Poseidon orbit has been uniquely maintained using both passive (non-propulsive) and active (propulsive) maneuvers. Furthermore, the orbit has been maintained using only the passive technique since the ninth orbit maintenance maneuver on January 15, 1996. Only nine orbit maintenance maneuvers have been required to maintain the ground track, including verification site over flights, since achieving the operational orbit on September 21, 1992 (mission requirement: 95% within +/- l km). During this period, a has varied within 7,714,429 +/- 7 m, while the inclination i periodically fluctuated in the range 66.0408 deg. +/- 0.0040 deg. The frozen orbit (required e < 0.001 and omega approximately equals to 90 deg.) has been maintained without any dedicated eccentricity maneuvers. The frozen eccentricity vector has completed two periodic cycles and it is currently tracing its third cycle (period approximately equals 26.7 months).

Bhat, R. S.↗

NASA NTRS1999

Spacecraft Onboard Software Maintenance: An Effective Approach which Reduces Costs and Increases Science Return

Flight software (FSW) is a mission critical element of spacecraft functionality and performance. When ground operations personnel interface to a spacecraft, they are dealing almost entirely with onboard software. This software, even more than ground/flight communications systems, is expected to perform perfectly at all times during all phases of on-orbit mission life. Due to the fact that FSW can be reconfigured and reprogrammed to accommodate new spacecraft conditions, the on-orbit FSW maintenance team is usually significantly responsible for the long-term success of a science mission. Failure of FSW can result in very expensive operations work-around costs and lost science opportunities. There are three basic approaches to staffing on-orbit software maintenance, namely: (1) using the original developers, (2) using mission operations personnel, or (3) assembling a Center of Excellence for multi-spacecraft on-orbit FSW support. This paper explains a National Aeronautics and Space Administration, Goddard Space Flight Center (NASA/GSFC) experience related to the roles of on-orbit FSW maintenance personnel. It identifies the advantages and disadvantages of each of the three approaches to staffing the FSW roles, and demonstrates how a cost efficient on-orbit FSW Maintenance Center of Excellence can be established and maintained with significant return on the investment.

Shell, Elaine M.↗

NASA NTRS2007

Four-Formation In-Track Configuration Maintenance Strategy

The aim of this paper is to present the analysis conducted by CNES for the maintenance of a formation made of several LEO satellites (typically 4) in several planes (typically 2), 100 km or so apart from each other. The along-track separations between the satellites have to be controlled to within 15 km thanks to orbit correction maneuvers supposed to be performed every 2 weeks. The main difficulty is related to solar activity which is expected to be close to its maximum for the entire mission s lifespan. As a matter of fact, a high solar activity makes orbit prediction harder, and makes it impossible to keep the altitude of the formation constant. Thus, a specific relative maintenance strategy had to be devised in order to meet the mission's requirements. The first part provides a few elements on the mission analysis process that has taken place. The method used for the evaluation of the maneuver frequency is detailed, based on the evaluation of the effects of atmospheric drag on the orbit. The second part is dedicated to the maintenance strategy that has been designed, and particularly to the computation of the reference orbits and of the velocity increments that enable the in-track inter-satellite distances to be maintained within the desired bounds. Finally a few simulation results are presented; they enable the performance of the maintenance strategy to be checked in a more realistic context.

Lamy, Alain↗

NASA NTRS2013

A Proposed Approach for Prioritizing Maintenance at NASA Centers

The National Aeronautics and Space Administration (NASA) manages a vast array of infrastructure assets across ten National Centers with a worth of at least 30 billion dollars. Eighty percent of this infrastructure is greater than 40 years old and is in degraded condition. Maintenance budgets are typically less than one percent of current replacement value (CRV), much less than the 2-4% recommended by the National Research Council. The maintenance backlog was 2.55 billion dollars in FY10 and growing. NASA s annual budgets have flattened and are at risk of being reduced, so the problem is becoming even more difficult. NASA Centers utilize various means to prioritize and accomplish maintenance within available budgets, though data is suspect and processes are variable. This paper offers a structured means to prioritize maintenance based on mission criticality and facility performance (ability of the facility to deliver on its purpose). Mission alignment is assessed using the current timeframe Mission Dependence Index and a measure of facility alignment with the 2011 NASA Strategic Plan for the long-term perspective. Facility performance is assessed by combining specific findings from a structured facility condition assessment and an assessment of actual functional output. These are then combined in a matrix to identify the facilities most critical to mission and able to deliver services. The purpose of this approach is to provide the best benefits for the available funding. Additionally, this rationale can also be applied to the prioritization of investment (recapitalization) projects so that the ultimate customers of this paper, the senior infrastructure managers at each NASA Center, are better able to strategically manage their capabilities.

Dunn, Steven C.↗

NASA NTRS2013

Shuttle Repair Tools Automate Vehicle Maintenance

Successfully building, flying, and maintaining the space shuttles was an immensely complex job that required a high level of detailed, precise engineering. After each shuttle landed, it entered a maintenance, repair, and overhaul (MRO) phase. Each system was thoroughly checked and tested, and worn or damaged parts replaced, before the shuttle was rolled out for its next mission. During the MRO period, workers needed to record exactly what needed replacing and why, as well as follow precise guidelines and procedures in making their repairs. That meant traceability, and with it lots of paperwork. In 2007, the number of reports generated during electrical system repairs was getting out of hand-placing among the top three systems in terms of paperwork volume. Repair specialists at Kennedy Space Center were unhappy spending so much time at a desk and so little time actually working on the shuttle. "Engineers weren't spending their time doing technical work," says Joseph Schuh, an electrical engineer at Kennedy. "Instead, they were busy with repetitive, time-consuming processes that, while important in their own right, provided a low return on time invested." The strain of such inefficiency was bad enough that slow electrical repairs jeopardized rollout on several occasions. Knowing there had to be a way to streamline operations, Kennedy asked Martin Belson, a project manager with 30 years experience as an aerospace contractor, to co-lead a team in developing software that would reduce the effort required to document shuttle repairs. The result was System Maintenance Automated Repair Tasks (SMART) software. SMART is a tool for aggregating and applying information on every aspect of repairs, from procedures and instructions to a vehicle s troubleshooting history. Drawing on that data, SMART largely automates the processes of generating repair instructions and post-repair paperwork. In the case of the space shuttle, this meant that SMART had 30 years worth of operations that it could apply to ongoing maintenance work. According to Schuh, "SMART standardized and streamlined many shuttle repair processes, saving time and money while increasing safety and the quality of repairs." Maintenance technicians and engineers now had a tool that kept them in the field, and because SMART is capable of continually evolving, each time an engineer put it to use, it would enrich the Agency-wide knowledge base. "If an engineer sees something in the work environment that they could improve, a repair process or a procedure, SMART can incorporate that data for use in future operations," says Belson.

Source record↗

NASA NTRSDate not supplied

Autonomous In-space Construction, Maintenance, and Reconfiguration Using Programmable Meta-Material

NASA ARC's Coded Structures Laboratory (CSL) is developing autonomous construction, maintenance, and reconfiguration technologies to meet long-duration and deep space infrastructure needs, in accordance with long-term NASA goals of "in-space reliance" and "mass-less exploration." We seek to achieve these capabilities by utilizing a "programmable meta-material" approach that integrates emerging advances in materials (mechanical meta-materials), manufacturing (cooperative mobile robotics), and autonomy (multi-agent planning algorithms). Through the ARMADAS project, we have shown assembly of high-performance engineered cellular materials using multiple cooperating mobile robotic assemblers. In this paper, we describe how such a programmable meta-material architecture may shift the paradigm of how we design, build, manufacture, and operate future space infrastructure and assets. The core of a programmable meta-material architecture consists of 3 main technology sub-areas: the structure, the assembly agents, and the assembly algorithms. We co-design these systems to ensure an adaptable system that can create and reconfigure structures from a base set of building block components. From this core technology, we can branch out and expand the capability of the system through additional secondary component types and robotic agents to perform activities such as inspections, maintenance, repair, payload installation, or perform power and communications interconnect. As these technologies mature, future designers will be able to utilize the system to rapidly integrate and operate assets in space or on planetary surfaces from a set of well-tested part library, or create their own modules to integrate into the system. A core trait to the development of this system is the automation approach. Because of the modular and functional discrete (pixel-like) nature of the structural system, a diverse set of powerful algorithms for analysis, planning, and simulation can be adapted and leveraged to optimize construction, maintenance, and dynamic reorganization (as hardware with programmable form and function). With an ability to free the design space from launch vehicle constraints and fundamentally shift how a mission is designed and conducted, we discuss the influence of a programmable meta-material architecture on mission design, build, and operations. For the "design phase", we discuss project lifecycle effects, costs, time, and performance. For the "build phase", we discuss reusability, ISRU, manufacturing, material logistics, and scalability. And for "operations", we discuss autonomy, maintenance and upgrades, reliability, and reconfiguration. Autonomy and modularity are the primary enabling traits of this system. Engineering systems that utilize a modular and reconfiguration building block approach such as digital communication and computation systems, currently lead all other areas of technology in size and complexity scalability. NASA is extending the benefits and flexibility of digital systems to hardware systems, to optimize materials lifecycle management and expand our space exploration mission capabilities.

in space assembly↗

DOE OSTI2024

Assessment of Cloud-based Applications for Enabling a Scalable Riskinformed Predictive Maintenance Strategy

The current light-water reactor fleet uses time-based maintenance strategies to achieve high-capacity factors. But to make nuclear more competitive in the energy market, these reactors could utilize emerging artificial intelligence (AI) and cloud computing technologies to achieve a cost-effective, predictive-maintenance strategy. This paper presents discussion and results on the application of cloud computing in the nuclear industry. The technical viability of cloud computing was analyzed using data from a boiling-water reactor’s safety relief valve. The models were hosted on three different systems: a local personal computer, Idaho National Laboratory’s high-performance computer system, and Microsoft Azure. The data were loaded and processed, and two types of models were trained in an A/B fashion. Based on the speed at which these actions were completed, it was determined that cloud computing affords adequate computing resources. Additionally, the computing power can scale with the demanded load. To enable cloud computing in the existing fleet, additional sensors, networks, and other requirements must be implemented to ensure a smooth transition from current maintenance strategies. However, the benefit is that the plants no longer need to manage their own servers, software, cybersecurity, and information technology support staff for in-house data analytics purpose. Many of these features can be offloaded to the cloud provider for a potential cost savings. Demonstrating how AI can improve the maintenance and operation of non-safety-related systems seems the likely path forward for implementing AI and cloud computing resources inside nuclear power plants.

azure↗

NASA NTRS2006

NASA Critical Facilities Maintenance Assessment

Critical Facilities Maintenance Assessment (CFMA) was first implemented by NASA following the March 2000 overtest of the High Energy Solar Spectroscopic Imager (HESSI) spacecraft. A sine burst dynamic test using a 40 year old shaker failed. Mechanical binding/slippage of the slip table imparted 10 times the planned force to the test article. There was major structural damage to HESSI. The mechanical "health" of the shaker had not been assessed and tracked to assure the test equipment was in good working order. Similar incidents have occurred at NASA facilities due to inadequate maintenance (e.g., rainwater from a leaky roof contaminated an assembly facility that housed a spacecraft). The HESSI incident alerted NASA to the urgent need to identify inadequacies in ground facility readiness and maintenance practices. The consequences of failures of ground facilities that service these NASA systems are severe due to the high unit value of NASA products.

maintenance↗

DOE OSTI2026

Cross-domain digital twin architecture for predictive maintenance via machine learning and Large Language Models

This research introduces a comprehensive framework for creating and deploying a digital twin platform for continuous monitoring and predictive maintenance within industrial settings. Through utilizing advanced technologies, including Unreal Engine 5, Unity 3D, the Message Queue Telemetry Transport protocol, Random Forest machine learning algorithms, and Large Language Models (LLMs), we establish a platform that digitally reproduces physical equipment and translates digital controls into real-world actions. This facilitates preventive maintenance approaches and improves operational effectiveness. The digital twin platform gathers sensor data from operational equipment, analyzes it using machine learning, and delivers practical insights to prevent potential malfunctions and enhance equipment performance. Furthermore, the incorporation of a web portal enables efficient monitoring and access to historical data, educational materials, and equipment status information. Preliminary findings indicate that digital twins can transform industrial equipment management and maintenance methodologies.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2026

Toward the application of the Risk-Based Maintenance approach to a hydrogen-fueled manufacturing plant

Safety, reliability, and maintenance of hydrogen-based equipment, including Risk-Based Maintenance (RBM), have recently gained increasing attention, as hydrogen, while key to decarbonizing hard-to-abate sectors, raises safety concerns. However, two literature gaps limit the development of risk-based strategies for hydrogen technologies. First, existing RBM methodologies do not account for hydrogen-specific components, such as electrolyzers, which differ from conventional equipment. Second, available studies on electrolyzer reliability remain largely qualitative or laboratory-scale. This study addresses these gaps by proposing an adapted RBM methodology tailored to hydrogen-fueled manufacturing facilities. Integrating qualitative tools (e.g., FMEA) with probabilistic models (e.g., Bayesian Networks) enables comprehensive hazardous scenarios identification and likelihood estimation. A conceptual layout of a glass furnace supplied by a 3 MW PEM electrolyzer is considered as a case study to demonstrate the feasibility of the adapted RBM framework in identifying high-risk components and enabling maintenance prioritization, potentially improving plant safety.

08 HYDROGEN↗

DOE OSTI2024

Demonstration and Evaluation of Explainable and Trustworthy Predictive Technology for Condition-based Maintenance

The domestic nuclear power plant (NPP) fleet has historically relied on labor-intensive and time-consuming predictive maintenance (PdM) programs, thus driving up operation and maintenance (O&M) costs to achieve high-capacity factors. Artificial intelligence (AI) and machine-learning (ML) can help simplify complex problems such as diagnosing equipment degradation to enable more effective decision-making efforts. The benefits of AI will be felt through more efficient plant O&M, improved work processes, and better integration of people and technology. Together, these benefits hold the promise to make nuclear power more sustainable by reducing O&M costs while improving employee engagement. While AI and ML technologies hold significant promise for the nuclear industry, there are challenges or barriers to their adoption. Explainability and trustworthiness of AI are two salient challenges that need to be addressed for wider deployment of these technologies in NPPs. This research focuses specifically on addressing the explainability and trustworthiness of AI technologies to advance the human, technical, and organization (HTO) readiness levels in adopting a risk-informed PdM strategy at commercial NPPs. In addition, this approach can be adapted to enhance the acceptability of AI in other nuclear applications with a few application-specific modifications. The technical approach ensuring wider adoption of AI technologies was developed by Idaho National Laboratory (INL)—in collaboration with Public Service Enterprise Group (PSEG), Nuclear, LLC—by utilizing the circulating water system (CWS) at two PSEG-owned plant sites for demonstration. Focused user studies were performed in collaboration with subject matter experts (SMEs) from PSEG and other nuclear domains to enhance human and organization readiness by building trust in AI-informed technologies. VIsualization for PrEdictive maintenance Recommendation (VIPER)—a Battelle Energy Alliance, LLC, copyrighted software—was developed and expanded to provide a user-centric visualization by incorporating inputs from the collaborating utility, human factors engineering guidelines, and data analysts. The VIPER software enables users, who may be unfamiliar with ML in general, to be interactively engaged by asking technical questions about PdM, work orders, diagnosis results and their confidence levels, the kind of data being used, and the types of ML algorithms employed. This interactive engagement enhances explainability and builds trust. One of the enabling accomplishments was the integration of large language models (LLMs), both text-based and vision-based, in the VIPER software.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2016

Staffing Strategies for Maintenance of Critical Software Systems at the Jet Propulsion Laboratory

The Mission Design and Navigation Software Group at the Jet Propulsion Laboratory (JPL) maintains mission critical software systems. We have good empirical data and models for maintenance demand—when defects will occur, how many and how severe they will be, and how much effort is needed to address them. However, determining the level of staffing needed to address maintenance issues is an ongoing challenge and is often done ad-hoc. There are two common strategies are (1) reactive – add/remove staff as needed to respond to maintenance issues, and (2) capacitive – retain a given staff size to address issues as they occur, proactively address issues and prevent defects.

software maintenance↗

DOE OSTI2024

Enhancing PV Inverter Reliability Through Predictive Maintenance: Insights from Retrofitting of PV Inverters

Photovoltaic (PV) systems represent a cornerstone in the global shift toward sustainable energy generation, with inverters serving as the crucial link between solar panels and the grid. Despite their pivotal role, inverters are susceptible to failures, contributing significantly to maintenance events and operational disruptions in large-scale PV plants. This white paper investigates the importance and methodologies of predictive maintenance strategies that monitor the component-level pre-failure signatures on PV inverters. Through a comprehensive survey of literature and industry professionals, insights on preventive maintenance and retrofitting practices have been gathered. The expert elicitation helps shed light on common challenges and opportunities for improving PV system reliability, particularly inverter reliability. By addressing these challenges, the white paper aims to enhance the long-term viability and effectiveness of solar PV plants in the renewable energy landscape, contributing to the global transition toward environmentally friendly energy generation.

14 SOLAR ENERGY↗

DOE OSTI2025

Rooftop Unit (RTU) Maintenance Guide

The commercial buildings industry has long emphasized affordability, energy efficiency, and useful service life in rooftop unit (RTU) equipment. The trade-offs between these characteristics can impact decisions about the initial cost of equipment and ongoing operating costs. Often, the desire for lower initial costs leads to adoption of low-efficiency systems or neglect of proper maintenance in the interest of short-term cost savings. Maintenance of these systems is a critical step to ensure system efficiency and reliability, low operating costs, and a reasonable payback period. This guide is intended for facility managers who own or are interested in purchasing and installing RTUs and need to familiarize themselves with the maintenance requirements. This resource contains best practices, important considerations, and additional information related to commercial RTU equipment, but does not replace manufacturer-specific instructions.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Using a Large Language Model for Accurate Technical Language Generation in the Predictive Maintenance of Circulating Water Systems in Nuclear Power Plants

Machine learning (ML) methods for predictive maintenance (PdM) are emerging as effective proactive strategies for diagnosing equipment degradation and enabling effective decision-making. However, explainability and trustworthiness of artificial intelligence are two salient challenges that need to be addressed for wider deployment of these technologies in nuclear power plants (NPPs). Large language models (LLMs) offer a unique approach to tackle these challenges by explaining PdM, work orders, diagnosis results, and ML algorithms to users, who may not be familiar with ML and PdM in general. Moreover, by dynamically retrieving relevant information from technical documents and evaluating factuality of LLM generation, the accuracy and relevance of LLM generations can be improved. This work demonstrates using LLMs to explain the causes and consequences of circulating water system failures based on multiyear NPP work orders. This work tests the capability of multimodal LLM approaches in explaining the differences in the circulating water system from both the Salem and Hope Creek NPPs using both text and image resources. This work also demonstrates the use of multimodal LLMs in describing the diagnosis tab of a predictive maintenance software named VIsualization for PrEdictive maintenance Recommendation (VIPER) to users.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Maintenance strategy, structural design, and site layout of the ST-E1 fusion power plant

An effective fusion reactor maintenance scheme enables safe operations and short downtimes. This in turn leads to high availability, which is critical to the commercial viability of a power-producing plant. In tokamak-based fusion power plants, the chosen maintenance approach has a significant impact on the spatial design of the tokamak, as well as the surrounding infrastructure, and therefore needs to be considered from the outset. Tokamak Energy has developed a pre-concept design of a fusion power plant, ST-E1. This work describes the major drivers and constraints that have been considered, presents the tokamak architecture and chosen maintenance regime, and discusses how this enables the plant’s two-phased approach to demonstrating commercial operations. It also shows the implications for the design of other systems areas, in particular the machine structural arrangement and bioshield and hot cell layout. The reactor core segmentation and removal scheme replaces entire toroidal segments radially through a large vacuum port, along a single axis only. The result is a change-tolerant machine and plant layout that can accommodate the evolving designs of the tokamak.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

Identification of Hydrogen Rail Maintenance Facility Hazards

Maintenance facilities for hydrogen rail, the activities conducted within such facilities, and how these activities differ from ordinary rail or hydrogen vehicle maintenance are currently being considered for the hazards specific to hydrogen. By performing a hazard and operability study (HAZOP) on numerous potential maintenance and repair scenarios, select low, medium, and high risk hazards relevant to hydrogen rail systems in such environments have been identified. The analysis resulted in 79 unique HAZOP scenarios: one scenario in the high risk category, 43 in the medium risk category, and 35 in the low risk category. Notably, large accidental releases of hydrogen due to tank rupture, aberrant defueling processes, or relief device opening within a facility are important low likelihood consequences that should nevertheless be appropriately prevented and mitigated.

08 HYDROGEN↗

DOE OSTI2026

National Solar Thermal Test Facility: Operations & Maintenance Report

The NSTTF O&M Project continues the operation and maintenance activities of the existing critical capabilities and infrastructure at the NSTTF. This project is to support and assure the success of Solar Heat for Industrial Process in the United States and the larger global community by ensuring the NSTTF is a safe and operational facility. The primary goal of this project will be to maintain the solar tower and heliostat field while also allowing NSTTF staff to improve processes for operations and maintenance. This includes expanding our preventative maintenance program, inventory systems, and our data sharing capabilities. Additionally, this will support an outreach program with regular seminars, sharing of data, and the release of open-source software to support heliostat metrology

14 SOLAR ENERGY↗