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DOE OSTI2021

Intelligent Prediction of States in Multi-port Autonomous Reconfigurable Solar power plant (MARS)

In power electronics, prediction of states may be used for identification of faults, determination of aging of components, identification of bad data measurements, among others. Prediction of states in power electronics have broadly been based on: (a) physics-based models, (b) data-driven models, and (c) hybrid models. In this paper, data-driven approaches are presented for intelligent prediction of states in multi-port autonomous reconfigurable solar power plant (MARS) and compared. The data-set needed to train the data-driven models based on artificial intelligence (AI) algorithms has been identified and the trained models are evaluated under different extrapolated normal and abnormal operating conditions. The AI algorithms include nonlinear auto-regressive exogenous model (NARX), spiking neural networks (SNN), and decision tree. The models are compared and contrasted. The best model (NARX) is evaluated under different normal and abnormal operating conditions that have indicated accurate prediction.

Debnath, Suman↗

DOE OSTI2025

Towards a Robust Adaptive Digital Twin for Fusion Applications

The development of a digital twin system for fusion applications is essential for enhancing the prediction, analysis, and optimization of complex plasma processes. Machine learning (ML), particularly deep learning has demonstrated strong capabilities in modeling such highly nonlinear and intricate systems. However, two critical challenges limit the deployment of deep learning-based digital twins: Uncertainty Quantification (UQ) and data drift. UQ is vital for ensuring trustworthy predictions, especially in decision-support scenarios. Additionally, data-driven models are often sensitive to changes in the underlying data distribution, such as shot-to-shot variations in fusion experiments, which can lead to performance degradation over time. To address these challenges, we are developing an uncertainty-aware, adaptive digital twin framework. Our approach incorporates deep learning models enhanced with Gaussian Process approximations for predictive uncertainty estimation, coupled with an online learning mechanism that enables continuous model adaptation to new experimental data. This adaptive capability allows the data driven models to respond effectively to evolving plasma behaviors and equipment conditions. Specifically, to mitigate the effects of shot-to-shot drift, our system updates itself incrementally as new data becomes available, improving both robustness and fidelity. Our vision is to evolve this data driven model into a self-sustaining digital twin system that leverages UQ based feedback to continuously refine itself and potentially support real-time decision making. This presentation will cover a brief background on uncertainty quantification for ML, our ongoing effort on development of UQ capabilities for ML, our data science pipeline from data collection to model development and analysis and online learning framework for modeling coil deflection at DIII-D. I will also briefly touch upon opportunities and challenges in development of digital twin framework.

Sammuli, Brian [General Atomics]↗

DOE OSTI2022

Robust Carbon Dioxide Plume Imaging Using Joint Tomographic Inversion of Seismic Onset Time and Distributed Pressure and Temperature Measurements (Final Report)

We develop and demonstrate rapid and cost-effective methodologies for spatiotemporal tracking of CO2 plumes during geologic sequestration using joint inversion of seismic data and distributed pressure and temperature measurements. Key elements of our methodology are: (a) a computationally efficient approach to pressure and temperature propagation, (b) analysis of time lapse seismic data using a novel ‘seismic onset time’ approach to detect fluid front propagation, and (c) data assimilation and uncertainty assessment via joint inversion of pressure, temperature and time lapse seismic data, and (d) validating the numerical tomographic inversion using a CO2 injection demonstration projects, specifically data collected from the from the Petra Nova Parish Holdings CCUS project in the West Ranch Field, Texas and the Chester-16 reef CO2 injection site in Northern Michigan which is part of the DOE Midwestern Carbon Sequestration Project. The research team is led by Texas A&M University and includes Battelle as a subcontractor with support from Shell, Anadarko, Chevron and JX Nippon. A carbon dioxide (CO2) water-alternating-gas (WAG) pilot was conducted to gain insights into tertiary oil recovery potential via CO2 flood in the West Ranch Field as part of the Petra Nova project, the world’s largest post-combustion CO2 capture and utilization initiative. With a fluvial formation geology and large contrasts in permeability, this is a challenging and novel application of CO2 enhanced oil recovery (EOR). We build a predictive dynamic model of the subsurface that incorporates the multiphase and compositional data acquired during the pilot operation. The calibrated model is used for the carbon dioxide plume imaging. The study began with an initialization of the pilot sector model extracted from a calibrated full-field model. The pilot model calibration follows a two-step hierarchical workflow. First, we performed a large-scale update of the permeability distribution by integrating available bottomhole pressure and multiphase production data. In the second step, local permeability field is fine-tuned using a streamline-based method to match CO2 breakthrough times at the producers. The predictive capability of the calibrated model was verified through two blind validation tests: (1) the model showed good agreement with saturation logs acquired at two observation wells; and (2) the model reproduced the CO2 recovery as a fraction of the injected CO2. The use of seismic onset times has shown great promise for integrating near-continuous seismic surveys for updating geologic models. In this study, we analyze the impact of seismic survey frequency on the onset time approach aiming to extend the application of onset time to infrequent seismic surveys. In addition, we quantitatively examine the nonlinearity of the onset time method and compare it to the commonly used amplitude inversion method. We carry out a sensitivity analysis of seismic survey frequency based on the complete seismic survey data (over 175 surveys) of steam injection in a heavy oil reservoir (Peace River Unit) in Canada. Our results show that an adequate onset time map can be obtained from the infrequent seismic surveys by interpolation between seismic surveys as long as there is no change in the dominant underlying physics between the successive surveys. The study also shows that nonlinearity of the onset time method can be -smaller than that of the amplitude inversion method by several orders of magnitude. Application to the Brugge benchmark case shows that the onset time method obtains comparable permeability update as the traditional seismic amplitude inversion method with faster computation and improved convergence characteristics. We extend the streamline-based data integration approach to incorporate distributed temperature sensor (DTS) data using the concept of thermal tracer travel time. Then, a hierarchical workflow composed of evolutionary and streamline methods is employed to jointly history match the DTS and pressure data. Finally, CO2 saturation and streamline maps are used to visualize the CO2 plume movement during the sequestration process. The hierarchical workflow is applied to a carbon sequestration project in a carbonate reef reservoir within the Northern Niagaran Pinnacle Reef Trend in Michigan, USA. The monitoring data set consists of distributed temperature sensing (DTS) data acquired at the injection well and a monitoring well, flowing bottom-hole pressure data at the injection well, and time-lapse pressure measurements at several locations along the monitoring well. The history matching results indicate that the CO2 movement is mostly restricted to the intended zones of injection which is consistent with an independent warm-back analysis of the temperature data. In addition to employing simulation models and inverse methods for CO2 plume imaging, we also initialized a data-driven technology for detecting inter-well connectivity based on production and pressure data. Our machine-learning framework is built on the statistical recurrent unit (SRU) model and interprets well-based injection/production data into inter-well connectivity without relying on a geologic model. We test it on synthetic and field-scale CO2 EOR projects utilizing the water-alternating-gas (WAG) process. The validation of the proposed data-driven inter-well connectivity assessment is performed using synthetic data from simulation models where inter-well connectivity can be easily measured using the streamline-based flux allocation. The SRU model is shown to offer excellent prediction performance on the synthetic case. Despite significant measurement noise and frequent well shut-ins imposed in the field-scale case, the SRU model offers good prediction accuracy, the overall relative error of the phase production rates at most producers ranges from 10% to 30%. It is shown that the dominant connections identified by the data-driven method and streamline method are in close agreement. Texas A&M University, the lead organization in the project, was primarily responsible for the development of tomographic approaches for CO2 plume mapping in conjunction with distributed pressure, temperature and seismic onset time data. Battelle, as a subcontractor, was primarily responsible for the development of analytical and empirical methods for analyzing transient injection rate and pressure data from point/line sources such as injection and monitoring wells. An additional area of emphasis for Battelle was the use of machine learning for such tasks as inferring reservoir connectivity information from injection-production data, and identifying variable importance for machine learning-based proxy models developed from full-physics simulations. The two organizations also collaborated on the application of the tomographic inversion methodology for a field data set.

02 PETROLEUM↗

DOE OSTI2023

Black and gray box learning of amplitude equations: Application to phase field systems

Here, we present a data-driven approach to learning surrogate models for amplitude equations and illustrate its application to interfacial dynamics of phase field systems. In particular, we demonstrate learning effective partial differential equations describing the evolution of phase field interfaces from full phase field data. We illustrate this on a model phase field system, where analytical approximate equations for the dynamics of the phase field interface (a higher-order eikonal equation and its approximation, the Kardar-Parisi-Zhang equation) are known. For this system, we discuss data-driven approaches for the identification of equations that accurately describe the front interface dynamics. When the analytical approximate models mentioned above become inaccurate, as we move beyond the region of validity of the underlying assumptions, the data-driven equations outperform them. In these regimes, going beyond black box identification, we explore different approaches to learning data-driven corrections to the analytically approximate models, leading to effective gray box partial differential equations.

42 ENGINEERING↗

DOE OSTI2024

Experimental Setup and Learning-Based AI Model for Developing Accurate PV Inverter Models

The integration of power electronics-based interfaces presents challenges due to the absence of detailed models and the high computational complexity. Generic models used in system studies lack accuracy in capturing converter dynamics. This paper proposes a data-driven approach developed from experimental setup data. This approach enhances accuracy in photovoltaic inverter modeling. We used two types of PV inverters in the experiment. The recorded experimental data undergo processing through a machine learning model. Results from the model trained through machine learning is also presented.

artificial intelligence↗

DOE OSTI2021

Kimberlina 1.2 Velocity Models and Seismic Data

Kimberlina 1.2 Velocity model and synthetic seismic data, produced in collaboration of teams at the National Energy Technology Laboratory, Los Alamos National Laboratory, and Lawrence Livermore National Laboratory through the National Risk Assessment Partnership. Data is associated with the following publication: Zheng Zhou, Youzuo Lin, Zhongping Zhang, Yue Wu, Zan Wang, Robert Dilmore, and George Guthrie, "A Data-Driven CO2 Leakage Detection Using Seismic Data and Spatial-Temporal Densely Connected Convolutional Neural Networks," International Journal of Greenhouse Gas Control, Vol 90, 2019. The Kimberlina 1.2 Velocity models were produced by Zan Wang, Robert Dilmore, William Harbert, and Lianjie Huang at NETL. The following citations are directly related to the creation of the velocity models: Wang, Z. Harbert, W., Dilmore, R., Huang, L. Modeling of time-lapse seismic monitoring using CO2 leakage simulations for a model CO2 storage site with realistic geology: Application in assessment of early leak-detection capabilities. International Journal of Greenhouse Gas Control. V. 76, September 2018, Pages 39-52. https://doi.org/10.1016/j.ijggc.2018.06.011 Wang, Z., Dilmore, R., Harbert, W. Inferring CO2 saturation from synthetic surface seismic and downhole monitoring data using machine learning for leakage detection at CO2 sequestration sites. International Journal of Greenhouse Gas Control, V. 100, September 2020. https://doi.org/10.1016/j.ijggc.2020.103115 The velocity models were built based on the Kimberlina 1.2 aquifer impact data which is associated with the following publications: Buscheck, T.A., Mansoor, K., Yang, X., Wainwright, H., and Carroll, S. (2019). Downhole pressure and chemical monitoring for CO2 and brine leak detection in aquifers above a CO2 storage reservoir. International Journal of Greenhouse Gas Control. 91. 102812. 10.1016/j.ijggc.2019.102812. Xianjin Yang, Thomas A. Buscheck, Kayyum Mansoor, Zan Wang, Kai Gao, Lianjie Huang, Delphine Appriou, Susan A. Carroll, Assessment of geophysical monitoring methods for detection of brine and CO2 leakage in drinking water aquifers, International Journal of Greenhouse Gas Control, Volume 90, 2019, 102803, ISSN 1750-5836, https://doi.org/10.1016/j.ijggc.2019.102803 The synthetic seismic data was produced by Youzuo Lin and team at LANL, and are associated with the following citations: Jordan, P. D., and J. L. Wagoner. Characterizing Construction of Existing Wells to a CO2 Storage Target: The Kimberlina Site, California. Zheng Zhou, Youzuo Lin, Zhongping Zhang, Yue Wu, Zan Wang, Robert Dilmore, and George Guthrie, "A Data-Driven CO2 Leakage Detection Using Seismic Data and Spatial-Temporal Densely Connected Convolutional Neural Networks," International Journal of Greenhouse Gas Control, Vol 90, 2019.

CO2 Leakage↗

DOE OSTI2025

Digital twin framework for PIP-II linac: AI-driven multi-scale modeling from ion source to 800 MeV

The PIP-II superconducting linac at Fermilab is designed to deliver multi-megawatt proton beams for neutrino physics and other high-intensity applications. To expedite commissioning and enhance operational reliability, we have developed an EPICS-based data flow framework that seamlessly integrates digital twins (DT) with physical twins (PT). These digital twins comprise high-fidelity beam dynamics models or data-driven surrogate models connected to their physical counterparts through real-time diagnostics and advanced machine-learning algorithms.Central to this framework is Linac_Gen, an accelerated simulation tool that incorporates convolutional neural networks, random forests, and genetic algorithms to provide up to a tenfold speedup in optimizing the accelerator geometry model. An EPICS translator layer ensures interoperability by efficiently mapping lattice parameters across diverse simulation platforms.Our EPICS-based framework supports multiple operational modes—monitoring, passive learning, closed-loop control, and online learning—covering the entire machine lifecycle. By leveraging HPC resources and multi-objective optimization techniques, the digital twin enables adaptive trajectory correction, real-time fault detection, and predictive modeling of beam stability. This comprehensive approach paves the way for robust, high-intensity operation and data-driven accelerator R&D at Fermilab.

Pathak, Abhishek [Fermilab]↗

DOE OSTI2024

Utilization of an Advanced Sensor network to determine fuel heating value and Real-Time net unit heat rate during transient operation

Coal-fired utility boilers are being increasingly used as variable electricity generation to resolve the imbalance in the energy market from the expansion of intermittent renewable energy. The frequent transient operation required to meet residual energy demand has created a challenge for coal-fired units to operate efficiently. This work utilizes an advanced sensor network (ASN) to calculate net unit heat rate (NUHR) of a coal-fired boiler in real time through combustion calculations and statistical correlations to provide the tools for optimizing dynamic operation. Real-time heating values that were necessary to determine fuel input energy to calculate accurate NUHR were found using both fundamental and data-driven methods. Real-time NUHR shows distinct shifts that reflect changes in process conditions that will improve the ability to optimize transient operation. Data-driven heating value correlations had 24% lower root mean square error (RMSE) than the fundamental combustion calculation approach when compared to daily retrospective proximate analysis. Furthermore, the data-driven method RMSE improved by 7% with the inclusion of ASN data. Future work is to validate by comparing unit performance with and without the inclusion of NUHR as a control parameter for the dynamic neural network.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Progress Towards Interpretable Machine Learning-based Disruption Predictors Across Tokamaks

In this paper we lay the groundwork for a robust cross-device comparison of data-driven disruption prediction algorithms on DIII-D and JET tokamaks. In order to consistently carry on a comparative analysis, we define physics-based indicators of disruption precursors based on temperature, density, and radiation profiles that are currently missing for DIII-D data. These profile-based indicators are shown to well-describe impurity accumulation events in both DIII-D and JET discharges that eventually disrupt. Thanks to the univariate analysis on the features used in such data-driven applications on both tokamaks, we are able to statistically highlight differences in the dominant disruption precursors: JET with its ITER-like wall is more prone to impurity accumulation events, while DIII-D is more subject to edge cooling mechanisms that destabilize dangerous MHD modes. Even though the analyzed datasets are characterized by such intrinsic differences, we show how data-driven algorithms trained on one device can be used to predict and interpret disruptive scenarios on the other. As long as the destabilizing precursors are diagnosed in a device-independent way, the knowledge that data-driven algorithms learn on one device can be used to explain a disruptive behavior on another device.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

A large-scale benchmarking of deterministic and stochastic derivative-free optimization algorithms

This presentation summarizes our work in the PrOMMiS project on benchmarking of data-driven optimization algorithms and their applications in self-driving laboratories. This work supports the broader project goal of accelerating the identification of promising separation methods and operating conditions for critical minerals separation processes. We present a systematic benchmarking study of 42 data-driven optimization algorithms on a broad collection of 502 test problems. The results identify BAM, GLCCLUSTER, and MULTIMIN as the most effective optimization solvers, with BAM showing the highest overall performance and solving more than 80% of the benchmark problems. The study also shows that no single solver consistently outperforms the others across all problem types, indicating that our future laboratory applications may benefit from using a small set of strong solvers rather than relying on a single method. The presentation also illustrates an in-silico chemical reactor case study showing that data-driven optimization methods can guide autonomous experimentation in a self-driving laboratory and identify optimal operating conditions within a small number of experiments. Overall, the results provide a basis for selecting efficient optimization methods and demonstrate the practical use of data-driven optimization in self-driving laboratory workflows.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Algorithm-guided experimentation for autonomous AI systems in self-driving laboratories

36 MATERIALS SCIENCE↗

DOE OSTI2016

Distribution-Agnostic Stochastic Optimal Power Flow for Distribution Grids

This paper outlines a data-driven, distributionally robust approach to solve chance-constrained AC optimal power flow problems in distribution networks. Uncertain forecasts for loads and power generated by photovoltaic (PV) systems are considered, with the goal of minimizing PV curtailment while meeting power flow and voltage regulation constraints. A data- driven approach is utilized to develop a distributionally robust conservative convex approximation of the chance-constraints; particularly, the mean and covariance matrix of the forecast errors are updated online, and leveraged to enforce voltage regulation with predetermined probability via Chebyshev-based bounds. By combining an accurate linear approximation of the AC power flow equations with the distributionally robust chance constraint reformulation, the resulting optimization problem becomes convex and computationally tractable.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

Operator inference for non-intrusive model reduction with quadratic manifolds

This paper proposes a novel approach for learning a data-driven quadratic manifold from high-dimensional data, then employing this quadratic manifold to derive efficient physics-based reduced-order models. The key ingredient of the approach is a polynomial mapping between high-dimensional states and a low-dimensional embedding. This mapping consists of two parts: a representation in a linear subspace (computed in this work using the proper orthogonal decomposition) and a quadratic component. The approach can be viewed as a form of data-driven closure modeling, since the quadratic component introduces directions into the approximation that lie in the orthogonal complement of the linear subspace, but without introducing any additional degrees of freedom to the low-dimensional representation. Combining the quadratic manifold approximation with the operator inference method for projection-based model reduction leads to a scalable non-intrusive approach for learning reduced-order models of dynamical systems. Further, applying the new approach to transport-dominated systems of partial differential equations illustrates the gains in efficiency that can be achieved over approximation in a linear subspace.

42 ENGINEERING↗

DOE OSTI2024

Physics-informed State-space Neural Networks for transport phenomena

This work introduces Physics -informed State -space neural network Models (PSMs), a novel solution to achieving real-time optimization, flexibility, and fault tolerance in autonomous systems, particularly in transportdominated systems such as chemical, biomedical, and power plants. Traditional data -driven methods fall short due to a lack of physical constraints like mass conservation; PSMs address this issue by training deep neural networks with sensor data and physics -informing using components' Partial Differential Equations (PDEs), resulting in a physics -constrained, end -to -end differentiable forward dynamics model. Further, through two in silico experiments - a heated channel and a cooling system loop - we demonstrate that PSMs offer a more accurate approach than a purely data -driven model. In the former experiment, PSMs demonstrated significantly lower average root -mean -square errors across test datasets compared to a purely data -driven neural network, with reductions of 44 %, 48 %, and 94 % in predicting pressure, velocity, and temperature, respectively. Beyond accuracy, PSMs demonstrate a compelling multitask capability, making them highly versatile. In this work, we showcase two: supervisory control of a nonlinear system through a sequentially updated state -space representation and the proposal of a diagnostic algorithm using residuals from each of the PDEs. The former demonstrates PSMs' ability to handle constant and time -dependent constraints, while the latter illustrates their value in system diagnostics and fault detection.

42 ENGINEERING↗

NASA NTRS2010

Evaluation of Anomaly Detection Capability for Ground-Based Pre-Launch Shuttle Operations

This chapter will provide a thorough end-to-end description of the process for evaluation of three different data-driven algorithms for anomaly detection to select the best candidate for deployment as part of a suite of IVHM (Integrated Vehicle Health Management) technologies. These algorithms were deemed to be sufficiently mature enough to be considered viable candidates for deployment in support of the maiden launch of Ares I-X, the successor to the Space Shuttle for NASA's Constellation program. Data-driven algorithms are just one of three different types being deployed. The other two types of algorithms being deployed include a "nile-based" expert system, and a "model-based" system. Within these two categories, the deployable candidates have already been selected based upon qualitative factors such as flight heritage. For the rule-based system, SHINE (Spacecraft High-speed Inference Engine) has been selected for deployment, which is a component of BEAM (Beacon-based Exception Analysis for Multimissions), a patented technology developed at NASA's JPL (Jet Propulsion Laboratory) and serves to aid in the management and identification of operational modes. For the "model-based" system, a commercially available package developed by QSI (Qualtech Systems, Inc.), TEAMS (Testability Engineering and Maintenance System) has been selected for deployment to aid in diagnosis. In the context of this particular deployment, distinctions among the use of the terms "data-driven," "rule-based," and "model-based," can be found in. Although there are three different categories of algorithms that have been selected for deployment, our main focus in this chapter will be on the evaluation of three candidates for data-driven anomaly detection. These algorithms will be evaluated upon their capability for robustly detecting incipient faults or failures in the ground-based phase of pre-launch space shuttle operations, rather than based oil heritage as performed in previous studies. Robust detection will allow for the achievement of pre-specified minimum false alarm and/or missed detection rates in the selection of alert thresholds. All algorithms will also be optimized with respect to an aggregation of these same criteria. Our study relies upon the use of Shuttle data to act as was a proxy for and in preparation for application to Ares I-X data, which uses a very similar hardware platform for the subsystems that are being targeted (TVC - Thrust Vector Control subsystem for the SRB (Solid Rocket Booster)).

Martin, Rodney Alexander↗

DOE OSTI2022

Seismic Waveform Inversion Capability on Resource-Constrained Edge Devices

Seismic full wave inversion (FWI) is a widely used non-linear seismic imaging method used to reconstruct subsurface velocity images, however it is time consuming, has high computational cost and depend heavily on human interaction. Recently, deep learning has accelerated it’s use in several data-driven techniques, however most deep learning techniques suffer from overfitting and stability issues. In this work, we propose an edge computing-based data-driven inversion technique based on supervised deep convolutional neural network to accurately reconstruct the subsurface velocities. Deep learning based data-driven technique depends mostly on bulk data training. In this work, we train our deep convolutional neural network (DCN) (UNet and InversionNet) on the raw seismic data and their corresponding velocity models during the training phase to learn the non-linear mapping between the seismic data and velocity models. The trained network is then used to estimate the velocity models from new input seismic data during the prediction phase. The prediction phase is performed on a resource-constrained edge device such as Raspberry Pi. Raspberry Pi provides real-time and on-device computational power to execute the inference process. In addition, we demonstrate robustness of our models to perform inversion in the presence on noise by performing both noise-aware and no-noise training and feeding the resulting trained models with noise at different signal-to-noise (SNR) ratio values. We make great efforts to achieve very feasible inference times on the Raspberry Pi for both models. Specifically, the inference times per prediction for UNet and InversionNet models on Raspberry Pi were 22 and 4 s respectively whilst inference times for both models on the GPU were 2 and 18 s which are very comparable. Finally, we have designed a user-friendly interactive graphical user interface (GUI) to automate the model execution and inversion process on the Raspberry Pi.

Manu, Daniel (ORCID:0000000154982677)↗

DOE OSTI2025

Development of Predictive Models for Advanced Reactor Autonomous Control

Advanced reactor designs including microreactors and small modular reactors will contribute to the clean production of cheap energy, and autonomous control for advanced reactors is an appealing option for reducing cost. However, there is a lack of industry experience applying autonomous control for advanced nuclear reactors. To accelerate the development and industry acceptance of autonomous control software for nuclear reactors, we aim to demonstrate autonomous control of the Purdue University research reactor (PUR-1) using INL-developed model predictive control (MPC) methods. To prepare for this demonstration, data-driven predictive models based on process data collected from PUR-1 have been developed and integrated with MPC and used to control a physics-based model of PUR-1. A data-driven dynamics model and a gated recurrent unit (GRU) network were both trained on process data from PUR-1. The dynamics model was shown to effectively control the reactor model with MPC when provided reactivity as a control variable but failed to control the model through the control rod positions. The GRU network produced more accurate predictions than the dynamics model when evaluated on operational data, and future work will include the evaluation of the GRU network in the controller.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

A Lizard-inspired Tube Inspector (LTI) Robot

This final report summarizes the research findings of the current project. This project is a collaboration between New Mexico State University (NMSU) as a lead (Recipient) and Arizona State University (ASU) as a Co-Recipient. Tubular structures are common components of boilers and heat exchangers in power plants. Over time, these components may suffer corrosion, cracks, and stress-corrosion cracks in either the body or the welded connections. A single tube leakage can cause an outage of several weeks. Regular inspection is a key safety factor when ensuring that power plants are maintained in reliable, operational condition. This inspection, however, is challenging, time-consuming, and in many cases impossible due to accessibility issues and safety concerns. Recent developments in robotic-based inspection can offer a great solution. Hard-to-reach places can be inspected without overhauling the unit, saving time and cost. Although several robots have been designed and implemented successfully for inspecting power plant components, in particular tubular structures, their mobility and flexibility are limited. Most of these robots use wheels for mobility which reduces their maneuverability of these robots. Moreover, they usually use magnets to attach to tubes which will not work on tubes with non-ferromagnetic materials. These robots usually carry measurement tools for a particular non-destructive testing (NDT) method such as ultrasound testing (UT) that requires a couplant to perform a point-by-point (scanning) inspection of the tubular structure. In this project, we developed a versatile lizard-inspired tube inspector (LTI) robot with embedded inspection sensing components for tube inspection which removes the need for point-by-point scanning of tube surface for crack and corrosion detection. Inspired by a “lizard”, the novelty of the current project is the integration of couplant-free ultrasound sensing and transmission, advanced data-driven defect detection and imaging, and friction-based mechanical mobility components in a single robot to eliminate a need for smooth surfaces and simple geometry for mobility and scanning. The LTI robot could replace the wheel-based approach with friction-based mobility to significantly increase the flexibility and maneuverability of the robot. The LTI robot can get into a power plant unit, such as a boiler, from a small area allowing it to access a component of interest for inspection (e.g., move on OD, curved and flat surfaces, non-ferromagnetic or ferromagnetic materials, and tubes with rough surfaces and complex geometries). Additionally, an advanced data-driven method using ultrasound data was pioneered to allow the robot to detect defects in the entire area between the robot’s multi-functional mobility system (grippers). Integrating a couplant-free ultrasound sensing in the robot’s grippers as well as using advanced data-driven methods allowed the LTI to detect defects in the entire cross-section of a tube using its grippers when stationary and when mobile.

20 FOSSIL-FUELED POWER PLANTS↗