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Systems Health Monitoring: Integrating FMEA into Bayesian Networks

The foreseeable high traffic density suggests that a large number of electric propulsion systems will enter the airspace, and that they will also operate at high frequency, e.g., large number of take offs and landings per unit time. The reliability of such critical systems is therefore key to ensure high safety standards in the low-altitude airspace. Diagnostic systems, which aim at identifying incipient faults, can mitigate unexpected failures or lower-than-expected reliability by performing early fault detection by monitoring the systems. A key element of fault diagnosis is fault detection and isolation (FDI), which complexity increases with the complexity of the system itself, namely the number of subsystems and components, interactions among sub-systems, and the number of sensors available. The proposed approach leverages combination of failure mode and effect analysis (FMEA) integrated with Bayesian networks, thus introducing dependability structures into a diagnostic framework to aid FDI. Faults and failure events from the FMEA are mapped within a Bayesian network, where network edges replicate the links embedded within FMEAs. The integrated framework enables the fault isolation process by identifying the probability of occurrence of specific faults or root causes given evidence observed through sensor signals. In this work, sub systems of Urban Air Mobility (UAM) type vehicle like avionics, structures, power-train etc. are taken into account to show the approach at the system level. This work integrates early design phase in the development of UAM type vehicles with diagnostic tools, which are often developed later in the product life-cycle, or retrofitted at a later time on systems. Failure mode and effect analysis (FMEA) derived for the system in the design phase is embedded within a Bayesian network (BN).

UAM↗
DOE OSTI2017

In Situ Disposal to Optimize Decommissioning Waste Management - 17455

Cavendish Fluor Partnership (CFP) is teaming with the UK government's Nuclear Decommissioning Authority (NDA) to explore opportunities for onsite disposal of structures and wastes from decommissioning of twelve Magnox nuclear sites. CFP is piloting implementation of draft guidance issued by the Environmental Agency (EA), Scottish Environmental Protection Agency (SEPA) and Natural Resources Wales (NRW) designed to optimise management of wastes generated in closing nuclear sites positioned across Scotland, Wales and England. Where it can be demonstrated to be the best overall solution for people and the environment, on-site / in situ disposal as an option for optimising waste management could save millions of pounds sterling in the overall costs for site closure as opposed to previous plans that required retrieval, packaging, transportation and offsite disposal of all radioactive wastes generated during site decommissioning. The UK government's Department for Business, Energy and Industrial Strategy (BEIS), NDA, and UK regulators are consulting with stakeholders on a proposal to amend legislation and enable better, more proportionate regulation of nuclear sites in the final stages of decommissioning and clean-up. Practical application of existing UK legislation typically means removing most, if not all, radioactive waste and residual contamination from the nuclear licensed site for disposal or management elsewhere, irrespective of any wider health and safety, social, environmental or economic considerations. Proposed changes to legislation would give greater weight to the environment agencies' guidance and provide for a more sustainable approach where optimization could include on-site/in situ disposal solutions and early opportunities to reuse land with appropriate regulatory oversight. Recent characterization activities at two reactor sites have identified areas of sub-grade low level contamination in structures and soil around used fuel ponds. CFP, a partnership of UK-based Cavendish Nuclear Limited and US-based Fluor Corporation, has initiated preliminary site modelling that indicates much of this material, including significant volumes of sub-grade structures would be conducive for in situ disposal under the new proposed guidance. Based on Fluor experience with similar decommissioning projects at US Department of Energy sites, CFP will look to leverage in situ disposal to optimise decommissioning waste management and consequently optimise overall facility decommissioning strategies. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Understanding Fission Gas Bubble Distribution and Zirconium Redistribution in Neutron-irradiated U-Zr Metallic Fuel Using Machine Learning

U-10wt.% Zr (U-10Zr) based metallic fuel is the leading candidate for next-generation sodium cooled fast reactor in United States. Currently, Idaho National Laboratory (INL) has been the leading national laboratory for research, development, and demonstration (RD&D) on metallic fuel. Advanced post-irradiation characterization will help to understand fuel microstructure and property change during irradiation, benefiting fuel qualification for commercial application. Characterization capabilities ranging from sub-nanometer to micrometer, such as scanning electron microscopy (SEM), focused ion beam (FIB) sampling, transmission electron microscopy (TEM) characterization, and local thermal conductivity microscopy (TCM), have been utilized recently on irradiated U-10Zr fuel samples to gain a better understanding of nuclear fuel microstructure and property evolution inside a reactor. The FIB/SEM coupled with energy dispersive X-ray spectroscopy (EDS) can capture the essential information to achieve better understanding of fuel behaviors. Inside a nuclear reactor, the phase and microstructure of U-10Zr is constantly changing under neutron bombardment. For example, the gaseous fission product atoms have a limited solubility inside fuel matrix and tend to precipitate out in bubble form, which not only contribute to fuel thermal conductivity degradation but also provide a shortcut for movement of fission products, i.e. lanthanides. The resultant deposition of lanthanides at the cladding inner surface will potentially trigger a chemical reaction/interaction between nuclear fuel and cladding at reactor operational conditions, threatening fuel integrity and safety. FIB/SEM coupled with EDS can provide the fission bubble information as well as probe into phase separation or Zr redistribution, which is fundamental to predict the fuel performance. With high velocity image data generating method, such as FIB/SEM, an automatic way to extract the microstructural information quantitively can better serve the needs from post irradiation characterization. A trained machine learning model, named Decision Tree, is employed to generate a bubble classifier and to categorize bubbles into three categories: isolated bubble, connected without lanthanides, and connected with lanthanides bubbles[3]. This work presents a showcase of this approach on six regions of a fuel cross-section along the radial temperature gradient. We obtained distributions of bubble categories and porosity rates along the six regions. Moreover, a secondary phase U-Zr2 was determined and found on regions 5 and 6. The secondary phase fraction was increasing from 15.61% in region 5 to 34.79% in region 6 based on this approach . This quantitative data offers insights into the lanthanide migration and potentially thermal conductivity degradation. This information from machine learning will be fed into fuel design code for better prediction of fuel performance.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Identification of Solid-Electrolyte Interphase Species by Joint Characterization of Li-Ion Battery Chemistry by Mass Spectrometry and Electrochemical Reaction Networks

The formation and stability of the solid-electrolyte interphase (SEI) play central roles in determining the long-term performance and safety of modern electrochemical energy storage systems. Despite decades of research, the SEI’s heterogeneous, dynamic, and multiphase nature has defied comprehensive molecular-level characterization, creating a critical knowledge gap that limits rational battery design. In this work, we introduce a computational−experimental framework that integrates high-throughput quantum chemistry calculations, data-driven electrochemical reaction networks (eCRNs), stochastic algorithms, and laser desorption/ionization Fourier transform ion cyclotron resonance mass spectrometry (LDI-FTICR-MS) to unravel SEI formation in carbonatebased electrolytes without imposing predefined mechanisms. We constructed the most comprehensive eCRN to date, spanning over 10,000 species and 209 million reactions. Through stochastic network analysis, we successfully recovered 27 species that were previously reported in the literature and predicted 28 novel SEI species nearly doubling our scientific knowledge in this area. Each new species was rigorously confirmed through advanced mass spectral analysis of its distinct molecular and isotopic signatures. We kinetically refined the formation pathways for a select set of both previously reported and novel SEI products, revealing kinetically feasible elementary reaction mechanisms with activation barriers below 1 eV. This computational−experimental approach deepens our molecular-level understanding of SEI chemistry by resolving which species form and through which decomposition mechanisms they emerge. Such knowledge provides the foundation necessary to connect electrolyte composition to the resulting SEI components, a critical step toward a more informed electrolyte development in next-generation lithium-based batteries.

25 ENERGY STORAGE↗
DOE OSTI2018

Development of a Pre-combustion CO 2 Capture Process Using High-Temperature PBI Hollow-Fiber Membranes

The overall goal of this research project was to develop a high-temperature, membrane-based CO 2 capture technology for coal gasification facilities and make progress toward meeting overall fossil energy performance goals of CO 2 capture with 95% CO 2 purity at a cost of electricity (COE) 30% less than baseline capture approaches. The primary objectives of the project were to evaluate, at a bench-scale size, a technically and economically viable CO 2 capture system based on a high-temperature polybenzimidazole (PBI) polymer hollow-fiber membrane (HFM) separation system, and to optimize the process for integration of that system into an integrated gasification combined cycle (IGCC) plant. The specific objectives of the proposed project are to: (1) fabricate high-performance PBI-HFMs for H 2 /CO 2 separation; (2) collect laboratory data for separating hydrogen from simulated synthesis gas using PBI-based membrane modules; (3) transfer the membrane fabrication technology to an industrial firm that specializes in the manufacture of HFMs; (4) fabricate membrane modules to process a syngas stream (50 kWth) equivalent to that of shifted gas from an oxygen-blown gasifier; (5) obtain design and steadystate performance data for membrane modules using syngas from an operating coal gasifier; (6) estimate the cost of CO 2 capture from pre-combustion gas streams integrated into a 550-MW (net) power plant; and (7) conduct a process environmental health & safety (EH&S) assessment.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2016

Neutronics of Advanced-Fuel Fusion Experiments with DT Triggering

Nuclear fusion studies are currently devoted to the Deuterium-Tritium (DT) fuel cycle, the easiest way to reach ignition. The recent stress on safety by the world community has stimulated the research on other fuel cycles, based on advanced reactions, such as Deuterium-Helium-3 (DHe). With DHe, it is not necessary to breed and fuel tritium. The DHe cycle has a very low presence of energetic fusion neutrons, due to DD and DT side reactions, and it has the possibility to obtain electrical power by direct energy conversion of the protons produced by the fusion reactions. DHe fusion has its own set of problems, such as the availability of {sup 3}He and the attainment of the higher plasma parameters. To explore the possibilities of DHe plasmas, a burning plasma experiment at high magnetic field and high plasma densities is particularly attractive. Ignitor is a proposed compact high-magnetic field tokamak, aimed at studying plasma-burning conditions in Deuterium-Tritium plasmas. The Ignitor experiment is designed to reach ignition under controlled DT burning conditions. The machine parameters have been established, on the basis of existing knowledge of the confinement properties of high density plasmas. The scientific goal of the Ignitor experiment is to approach, for the first time, the ignition conditions of a magnetically confined D-T plasma. However, the plasma density limit in Ignitor being well above the optimal density for DT ignition, is potentially suitable to the higher densities required for DHe burning. In fact, Ignitor has been designed also to explore conditions where 14.7-MeV protons and 3.6-MeV alpha particles produced by the DHe reactions can supply a significant amount of thermal energy to a well-confined plasma. In particular, Ignitor can sustain plasma currents exceeding those required to confine proton orbits at birth, and has more than sufficiently high densities so that the slowing-down time of both the protons and the DT alpha particles is shorter than the electron energy replacement time of the thermal plasma in which they are produced. Preliminary analyses show that a fusion power PF around 2 MW, may be reached. As a start, Ignitor can perform initial studies at the level of approximately 1 MW of power in charged particles from the DHe reaction in a mostly DT plasma. CANDOR, a design evolution of Ignitor in the direction of a reactor using a DHe fuel cycle, has been proposed; it is a feasibility study of a high-field DHe experiment of larger dimensions and higher fusion power than Ignitor, however still based on the core Ignitor technologies. The main characteristics of the CANDOR machine are the following: the major radius Ro is about double than Ignitor, plasma currents up to 25 MA with toroidal magnetic fields B{sub T} = 13 T can be produced. Unlike Ignitor, CANDOR would operate with higher values of poloidal beta around unity and the central part of the plasma column in the Second Stability region. The characteristic times over which the plasma discharge can be sustained are longer by more than a factor of 4 than those of Ignitor. To produce such a strong magnetic field in a larger machine, the toroidal field coils have been divided into two sets of coils and the central solenoid (air core transformer) is placed between them in the inboard part. In CANDOR, the DHe burning regime can be reached, by a combination of ICRF heating and alpha particle heating due to DT fusion reactions, which take the role of a sort of trigger. Thanks to this fact, and unlike other proposed DHe fusion experiments, CANDOR is capable of reaching DHe ignition using the existing technologies, and present knowledge of plasma confinement phenomena. With the initial use of DT, where tritium comprises some 50% of an initial lower density DT plasma, but is not added thereafter, the need for an intense auxiliary heating, which is one of the main technological drawbacks of DHe ignition, would be considerably alleviated, becoming feasible with the present technology. However, this method has the disadvantage of using tritium and of presenting a higher neutron flux (due to DT reactions) than 'pure' DHe plasmas, generating a neutron flux transient when passing from the initial DT trigger reaction to the final DHe burning plasma. However, for an experimental machine one-of-a-kind of relatively small dimensions, this is not an issue. (authors)

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2018

Regulatory and Licensing Strategy for Microreactor Technology

With electricity demand on the rise, an increase in the use of nuclear energy is needed in order to meet future energy demands. The use of nuclear energy will not only begin to positively address this demand, but will also mitigate the negative impacts of carbon-induced climate change and provide energy security to the United States. An appropriate option to address the increasing energy demand is the use of advanced reactor systems like microreactors. Microreactors, often referred to as special-purpose reactors or vSMRs, are neutronically simple, factory manufacturable, easily transportable, and designed to produce less than 20 MWt (for classification as Hazard Category 2 per 10 CFR 830, DOE STD 1027). These reactors are decentralized energy sources that have the ability to provide sustainable and affordable power to remote communities and to industrial users, while having self-contained geometry that requires very low maintenance care. In order for microreactors to be approved for operation, they must abide by and successfully complete a rigorous regulatory and licensing process monitored by the Nuclear Regulatory Commission (NRC), the Department of Energy (DOE), or the Department of Defense (DoD). Because microreactors are a relatively new and disruptive technology, there is no clear licensing path for them to follow. Current licensing frameworks are tailored specifically to large, traditional light water reactors (LWRs) that have been developed and understood by the nuclear industry for many years. Unlike LWRs, microreactors have major design differences, specifically in the materials, coolant, reflectors and potential technology applications used. They also have higher in-core operating temperatures, which have the potential to push the materials used past their allowable limits. Because they are much smaller, safety margins, the amount of space required for assembly, and the distances required to meet dose-based regulatory criteria can technically be altered to better fit their new size. The following strategies and recommendations are intended to assure that key licensing issues do not influence the path to microreactor development, demonstration, and commercialization: Nuclear Regulatory Commission • The NRC should address the lack of knowledge and support of risk informed decision-making concepts from staff members and continue to advance and communicate risk initiatives using their Risk Informed Steering Committee • More research should be done into whether or not microreactors, which are small Class 103 facilities, can be licensed using Class 104-type guidance (e.g., NUREG 1537) • The NRC should use frequency-consequence curves to incrementally reduce regulatory uncertainty and risk to facilitate future construction and operation of advanced reactor designs Department of Energy • The DOE should continue to implement their multi-step Phenomena Identification and Ranking Table process in order to help detect and recommend the major design and technology work needed for licensing future reactor systems • The DOE should consider a joint licensing approach with the NRC where microreactors first go through the DOE process, then finish with the NRC process, providing an advantage for both applicants and NRC staff Department of Defense • The DoD should invest in personnel with sufficient expertise, incorporate their military reactors into tactical power systems, and self-regulate using Section 91b of the Atomic Energy Act Transportation • Licensees should convert enriched uranium hexafluoride into metal or oxide at an enrichment facility and then transport them to a fabrication facility • To avoid transportation issues altogether, licensees should consider positioning the enrichment and fabrication facilities on the same site • The DOE should provide their support in developing new shipping packages for safe transport, criticality benchmark data needed to license high-assay low-enriched uranium fuel facilities and transport packages, and provide financial and technical help to the Department of Transportation; and, • The NRC should help transportation efforts by finalizing and developing guidance for implementing 10 CFR 73 and 10 CFR 74 specifically for Category 2 Special Nuclear Material.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2019

Development of an Experimental Approach for Thermal Testing in Bedded Salt - 19431

Safe and permanent isolation of used nuclear fuel (UNF) and high-level nuclear waste (HLW) is an integral component of the cradle-to-grave philosophy of radioactive waste management. Out of the multitude of rock types considered for the permanent deep disposal of nuclear waste (tuff, shale, granite, clay, and salt), salt has received significant interest particularly because of the advantage offered by salt as an impermeable and dry medium with self-sealing properties. The concept of HLW disposal in salt has been investigated through several testing campaigns in the U.S. and in Germany. Serval knowledge gaps still exist in our understanding of how brine is generated and how it transports under heat generating conditions. These knowledge gaps limit our ability to build a robust safety case for the disposal of heat generating waste in salt. The current manuscript reports on efforts performed to develop a field-testing campaign to study brine and water vapor migration in heated salt. The paper summarizes initial work done in a phased thermal testing program in bedded salt at the Waste Isolation Pilot Plant (WIPP), Carlsbad, New Mexico. The testing to date has been focused on existing boreholes and is being used to 'shakedown' the process for implementation of a more refined testing program that will be implemented in freshly drilled boreholes planned for FY2019. We designed and deployed a heater assembly that consisted of a packer, borehole deformation gauge, heater block, a network of thermocouples, and a pressure transducer setup to measure in situ temperature and pressure. The assembly was deployed in an existing borehole and several heating and cooling experiments were performed to test the performance of the different instruments fielded. We report on the results obtained for brine generation as a function of time and heating and cooling cycles and temperature evolution in the rock salt. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Probabilistic Methods for Cyclical and Coupled Systems with Changing Failure Rates

Advancements in nuclear system designs with automated control features provide many benefits, but can lead to complex coupled systems and dynamic failure scenarios. This is especially true for microreactor designs where components are not expected to be replaced during the reactor’s lifetime. Hence, the life of the system, in addition to the safety, needs to be evaluated. Modeling these sequences of time-dependent events requires addressing cyclical processes and changing failure rates in ways that represent the actual system dynamics in contrast to a single sampling for a component’s time to failure. This research presents two distinct analytical methods for several failure distributions that evaluate a final time to failure used for different scenarios where the time to failure must be sampled multiple times. The first method is used when evaluating a component whose failure rate increases due to an outside event after the initial sampling but before the initially sampled time to failure. The second method is used when evaluating multiple identical components or a component that has been replaced with a new identical version before the second sampling. The two methods were implemented in a few representative case studies developed in the dynamic probabilistic risk assessment tool Event Modeling Risk Assessment using Linked Diagrams. Overall, this paper provides guidelines on how these approaches give a more realistic and accurate dynamic probabilistic risk assessment of complex systems.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Modeling assisted synthesis of Zr-doped Li 3-x In 1-x Zr x Cl 6 with ultrahigh ionic conductivity for lithium-ion batteries

All-solid-state lithium-ion batteries (ASSLBs) are an important milestone for the future of energy storage because of their capability of impressive energy density and outstanding safety. However, oxide and sulfide solid-state electrolytes (SSEs) suffer from either low ionic conductivity or poor chemical stability. In contrast, halide-based SSEs, are promising as candidate materials owing to high conductivity, good stability, and broad cathode compatibility. Though element doping of the SSEs is an effective and common approach to further improve their electrochemical properties, dopant exploration and optimization through solely experimental trials are both costly and time-consuming. For this aspect, computational simulations for dopant element and concentration screening are adopted in this research and zirconium is selected as a suitable dopant for Li 3 InCl 6 . Further, the synthesized Li 2.75 In 0.75 Zr 0.25 Cl 6 exhibited Li ionic conductivity of 5.82 x 10 -3 Scm -1 at room temperature, which is the highest among reported halide SSEs. The ASSLB formed with Li 2 CoO 2 -Li 2.75 In 0.75 Zr 0.25 Cl 6 -Li/In delivers a high initial capacity of 129.3 mAh∙g -1 . Conclusively, this work provides an effective approach which combines computational modeling and experimental verification for the development of halide SSEs with improved stability and conductivity. The successful design approach and compelling results provide further possibilities and capabilities in future SSE research.

25 ENERGY STORAGE↗
NASA NTRS2020

Buckling of Thin-Walled Circular Cylinders

Recent industry and NASA experience with the development of launch vehicle structures have indicated a need for updated monographs for the design of buckling-critical structures that account for state-of-the-art structural configurations, material systems, and computational tools. This monograph provides an update to NASA SP-8007 (circa 1965, and 1968) and was prepared under the cognizance of the NASA Engineering and Safety Center (NESC). It summarizes all significant knowledge and experience accumulated from the NESC Shell Buckling Knockdown Factor (SBKF) Assessment (NESC Assessment #: 07-010-E) to date for use in the design of buckling-critical thin-walled circular cylinders. The format and terminology used in this monograph is similar to previous versions of NASA SP-8007 for ease of understanding and implementation. In addition, as with the design recommendations contained in the previous versions of NASA SP-8007, this monograph is to be regarded as a guideline to design and not as a NASA requirement, unless specified in formal program requirements. Furthermore, it is expected that the guidelines presented in this monograph will be updated as appropriate. Designers are advised to stay abreast of updates in the state-of-the-art and corresponding design criteria.

Buckling↗
DOE OSTI2020

Sensitivity Studies, Gap Analysis, and Benchmark Experiment Optimization for Reactor Applications

In regards to nuclear data, some reactor applications may lack validation experiments, which reduces confidence in predicted results. This is especially true for emerging advanced reactor, micro reactor, and Accelerator Driven System (ADS) designs. This work presents an approach to design new criticality experiments that have similar k eff cross section sensitivities to an application of interest. This process involves simulations to generate cross-section sensitivities to a parameter of interest (such as k eff ), a gap analysis to determine which existing benchmarks are most similar to the application, and an experiment optimization. This work focuses on cross-section sensitives and gap analysis for three examples relevant to the reactor physics community including a Travelling Wave Reactor (TWR) type-design, Kilopower (a space reactor design), and a lead-bismuth eutectic cooled accelerator-driven system (ADS) to transmute minor actinides.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2005

Business Intelligence Modeling in Launch Operations

This technology project is to advance an integrated Planning and Management Simulation Model for evaluation of risks, costs, and reliability of launch systems from Earth to Orbit for Space Exploration. The approach builds on research done in the NASA ARC/KSC developed Virtual Test Bed (VTB) to integrate architectural, operations process, and mission simulations for the purpose of evaluating enterprise level strategies to reduce cost, improve systems operability, and reduce mission risks. The objectives are to understand the interdependency of architecture and process on recurring launch cost of operations, provide management a tool for assessing systems safety and dependability versus cost, and leverage lessons learned and empirical models from Shuttle and International Space Station to validate models applied to Exploration. The systems-of-systems concept is built to balance the conflicting objectives of safety, reliability, and process strategy in order to achieve long term sustainability. A planning and analysis test bed is needed for evaluation of enterprise level options and strategies for transit and launch systems as well as surface and orbital systems. This environment can also support agency simulation .based acquisition process objectives. The technology development approach is based on the collaborative effort set forth in the VTB's integrating operations. process models, systems and environment models, and cost models as a comprehensive disciplined enterprise analysis environment. Significant emphasis is being placed on adapting root cause from existing Shuttle operations to exploration. Technical challenges include cost model validation, integration of parametric models with discrete event process and systems simulations. and large-scale simulation integration. The enterprise architecture is required for coherent integration of systems models. It will also require a plan for evolution over the life of the program. The proposed technology will produce long-term benefits in support of the NASA objectives for simulation based acquisition, will improve the ability to assess architectural options verses safety/risk for future exploration systems, and will facilitate incorporation of operability as a systems design consideration, reducing overall life cycle cost for future systems. The future of business intelligence of space exploration will focus on the intelligent system-of-systems real-time enterprise. In present business intelligence, a number of technologies that are most relevant to space exploration are experiencing the greatest change. Emerging patterns of set of processes rather than organizational units leading to end-to-end automation is becoming a major objective of enterprise information technology. The cost element is a leading factor of future exploration systems.

Bardina, Jorge E.↗
NASA NTRS2021

Best Practices Identified Through the Completion of UAS Flight Demonstrations

After several years of research into Detect and Avoid (DAA) and Command and Control (C2) systems for Unmanned Aircraft Systems (UAS), the National Aeronautics and Space Administration’s (NASA) UAS Integration into the National Airspace System project initiated a focused two-year effort along with the Federal Aviation Administration (FAA) and three industry partners to investigate remaining issues in the specification, test, certification and airspace integration to allow UAS operations in non-segregated airspace. The approach taken had the industry partners propose a flight demonstration approximating a commercial operation, while NASA helped, as needed, the partners through design and test phases and NASA observed interactions with the FAA. During this effort NASA collected best practices intended to be of value to similar UAS endeavors. These best practices can be divided into different sets, including practices that describe the relationship between business considerations to UAS design or describe several UAS development challenges. Another set includes best practices focused on navigating the UAS design and type certification processes. A third set includes best practices that relate to the design of the DAA system. Deploying DAA systems in this timeframe posed unique challenges. Commercial off-the-shelf DAA systems do not exist, necessitating custom development and, for two of the partners, the use of low-size, -weight, and -power (SWaP) sensors not completely specified for DAA. A fourth set of best practices relates to lost-link contingency planning. The final set of best practices relates to the design and testing of C2 systems and obtaining spectrum licenses. The UAS demonstrations were piloted remotely, and for all aspects of flight safety, a C2 system was required to communicate DAA and other UAS subsystem data to the remote pilot and to allow the pilot to issue commands to the vehicle. Throughout the course of this effort, the partners integrated prototype DAA and C2 systems into unmanned aircraft, tested those systems, and laid the groundwork for type certification programs that are expected to continue.

NASA↗
NASA NTRS2007

Development of the Functional Flow Block Diagram for the J-2X Rocket Engine System

The J-2X program calls for the upgrade of the Apollo-era Rocketdyne J-2 engine to higher power levels, using new materials and manufacturing techniques, and with more restrictive safety and reliability requirements than prior human-rated engines in NASA history. Such requirements demand a comprehensive systems engineering effort to ensure success. Pratt & Whitney Rocketdyne system engineers performed a functional analysis of the engine to establish the functional architecture. J-2X functions were captured in six major operational blocks. Each block was divided into sub-blocks or states. In each sub-block, functions necessary to perform each state were determined. A functional engine schematic consistent with the fidelity of the system model was defined for this analysis. The blocks, sub-blocks, and functions were sequentially numbered to differentiate the states in which the function were performed and to indicate the sequence of events. The Engine System was functionally partitioned, to provide separate and unique functional operators. Establishing unique functional operators as work output of the System Architecture process is novel in Liquid Propulsion Engine design. Each functional operator was described such that its unique functionality was identified. The decomposed functions were then allocated to the functional operators both of which were the inputs to the subsystem or component performance specifications. PWR also used a novel approach to identify and map the engine functional requirements to customer-specified functions. The final result was a comprehensive Functional Flow Block Diagram (FFBD) for the J-2X Engine System, decomposed to the component level and mapped to all functional requirements. This FFBD greatly facilitates component specification development, providing a well-defined trade space for functional trades at the subsystem and component level. It also provides a framework for function-based failure modes and effects analysis (FMEA), and a rigorous baseline for the functional architecture.

White, Thomas↗
NASA NTRS1997

Control Synthesis for a Class of Hybrid Systems Subject to Configuration-Based Safety Constraints

We examine a class of hybrid systems which we call Composite Hybrid Machines (CHM's) that consists of the concurrent (and partially synchronized) operation of Elementary Hybrid Machines (EHM's). Legal behavior, specified by a set of illegal configurations that the CHM may not enter, is to be achieved by the concurrent operation of the CHM with a suitably designed legal controller. In the present paper we focus on the problem of synthesizing a legal controller, whenever such a controller exists. More specifically, we address the problem of synthesizing the minimally restrictive legal controller. A controller is minimally restrictive if, when composed to operate concurrently with another legal controller, it will never interfere with the operation of the other controller and, therefore, can be composed to operate concurrently with any other controller that may be designed to achieve liveness specifications or optimality requirements without the need to reinvestigate or reverify legality of the composite controller. We confine our attention to a special class of CHM's where system dynamics is rate-limited and legal guards are conjunctions or disjunctions of atomic formulas in the dynamic variables (of the type x less than or equal to x(sub 0), or x greater than or equal to x(sub 0)). We present an algorithm for synthesis of the minimally restrictive legal controller. We demonstrate our approach by synthesizing a minimally restrictive controller for a steam boiler (the verification of which recently received a great deal of attention).

Heymann, Michael↗
DOE OSTI2021

Visualization of Solid-State Synthesis for Chalcogenide Na Superionic Conductors by in-situ Neutron Diffraction

Chalcogenide superionic sodium (Na) conductors are great potential as solid electrolytes (SEs) in all-solid-state Na batteries with advantages of high energy density and safety, and cost effectiveness. For solid Na-ion conductors, their crystal structures and ionically conductive properties are strongly influenced by the synthetic approaches and processing parameters. Thus, understanding the synthesis process is essential to control the structures and phases and thereby yields to Na-ion conductors with desirable properties. Thanks to the high-flux and deep-penetrating time-of-flight neutron diffraction (ND), we employed in situ experiments to track real-time structural changes of two chalcogenide SEs (Na 3 SbS 4 and Na 3 SbS 3.5 Se 0.5 ) during the solid-state synthesis. For these two conductors, the ND results reveal a fast one-step reaction for the synthesis and the molten process when heating up, and the recrystallization as well as the cubic-to-tetragonal phase transition up on cooling. Moreover, Se-doping is found to influence the reaction temperatures, lattice parameter and structure stability based on neutron experimental observations and theoretical simulation. This work presents a detailed structural study using in situ neutron diffraction technology for the solid synthesis process of chalcogenide Na-ion conductors, beneficial for the design and synthesis of new solid-state conductors.

25 ENERGY STORAGE↗
DOE OSTI2022

AI-Enabled Robots for Automated Nondestructive Evaluation and Repair of Power Plant Boilers. Final Report

Boiler failure could cause loss of life and safety issues, cost hundreds of thousands of dollars in equipment repairs, property damage and production losses, and drive up the cost of electric power. Boiler maintenance is challenging and risky for inspectors working on scaffolding in confined hazardous spaces inside of a boiler and sometimes the space is hard to access. The operation is also time-consuming due to the large area of vertical structures for inspection and the tremendous effort needed for scaffolding. Recently, the use of robotics (e.g., drones and crawlers) in power plants for maintenance is growing rapidly. However, the existing robotics solutions show two notable technological gaps: no live repair capability, and no Artificial Intelligence (AI) for smart autonomy. The objective of this project is to develop an integrated autonomous robotic platform that is equipped with compact non-destructive evaluation (NDE) sensors to perform live inspection, operates onboard repair devices to perform live repair, and uses AI for intelligent data fusion and predictive analysis for automated and smart spatiotemporal inspection, analysis and repair of the furnace walls in coal-fired boilers. The approach to achieve the objective includes developing NDE sensors with signal processing techniques, designing and evaluating repair devices for robots based on fusion and solid-state technologies, and an autonomous robotic platform that can attach to and navigate on boiler furnace walls using magnetic drive tracks. The robot is also powered by AI to automate data gathering (e.g., 3D mapping and damage localization) and predictive analysis. This project has advanced the state-of-the-art by providing technological breakthroughs including compact NDE and repair tools for robots, AI capabilities for smart autonomy, and a robotic platform for automated boiler maintenance. This project has great potential to result in significant benefits including limiting or eliminating the need to send operators to assess difficult-to-access or hazardous areas, enabling automated live inspection and repair, avoiding time consuming scaffolding (especially for partial maintenance during unplanned outage), collecting comprehensive and well-organized data smartly, and avoiding or limiting the need for onsite or remote piloting technicians. The impacts can be tremendous in terms of the time and cost savings, reducing the risk for human operators, and increasing boiler reliability, usability, and efficiency. In addition, by developing the new technologies on the autonomous inspection and repair robot, by involving multiple undergraduate and graduate students working together with the faculty members on this project, and by generating knowledge and building up collaborations with industrial partners, this effort will significantly update the education capabilities, support long-term fundamental research, and maintain the leadership of Colorado School of Mines and Michigan State University in energy fields.

20 FOSSIL-FUELED POWER PLANTS↗