Physics-Informed ROM Development for ISS EMU LLB-2 Condition-Based Monitoring
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Parameter inference↗
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Data-Mining Toolset Developed for Determining Turbine Engine Part Life Consumption
The current practice in aerospace turbine engine maintenance is to remove components defined as life-limited parts after a fixed time, on the basis of a predetermined number of flight cycles. Under this schedule-based maintenance practice, the worst-case usage scenario is used to determine the usable life of the component. As shown, this practice often requires removing a part before its useful life is fully consumed, thus leading to higher maintenance cost. To address this issue, the NASA Glenn Research Center, in a collaborative effort with Pratt & Whitney, has developed a generic modular toolset that uses data-mining technology to parameterize life usage models for maintenance purposes. The toolset enables a "condition-based" maintenance approach, where parts are removed on the basis of the cumulative history of the severity of operation they have experienced. The toolset uses data-mining technology to tune life-consumption models on the basis of operating and maintenance histories. The flight operating conditions, represented by measured variables within the engine, are correlated with repair records for the engines, generating a relationship between the operating condition of the part and its service life. As shown, with the condition-based maintenance approach, the lifelimited part is in service until its usable life is fully consumed. This approach will lower maintenance costs while maintaining the safety of the propulsion system. The toolset is a modular program that is easily customizable by users. First, appropriate parametric damage accumulation models, which will be functions of engine variables, must be defined. The tool then optimizes the models to match the historical data by computing an effective-cycle metric that reduces the unexplained variability in component life due to each damage mode by accounting for the variability in operational severity. The damage increment due to operating conditions experienced during each flight is used to compute the effective cycles and ultimately the replacement time. Utilities to handle data problems, such as gaps in the flight data records, are included in the toolset. The tool was demonstrated using the first stage, high-pressure turbine blade of the PW4077 engine (Pratt & Whitney, East Hartford, CT). The damage modes considered were thermomechanical fatigue and oxidation/erosion. Each PW4077 engine contains 82 first-stage, high-pressure turbine blades, and data from a fleet of engines were used to tune the life-consumption models. The models took into account not only measured variables within the engine, but also unmeasured variables such as engine health parameters that are affected by degradation of the engine due to aging. The tool proved effective at predicting the average number of blades scrapped over time due to each damage mode, per engine, given the operating history of the engine. The customizable tools are available to interested parties within the aerospace community.
Litt, Jonathan S.↗
Machine Learning–Based Condition Monitoring of a Circulating Water System of a Canadian Nuclear Plant
With the need to maintain long-term reliable energy using nuclear power plants, there is an underlying demand to ensure that the maintenance of plant components and systems is also done in an efficient and cost-effective manner. One way to achieve this is by moving from time-based maintenance to condition-based maintenance. The research presented in this paper focuses on applying statistical and machine-learning-based methods to capture anomalies within data for fault detection to further develop into condition monitoring. This paper focuses on system data for a circulating water system (CWS) of a pressurized heavy-water reactor for detecting anomalies. The different methodologies used for detecting and capturing anomalies in the CWS data are matrix profile, density-based spatial clustering of applications with noise (DBSCAN), and support vector machines (SVMs). Matrix profile and DBSCAN are used to distinguish between normal data and anomalous data. This paper presents a hybrid method using DBSCAN and SVM when a portion of the data is used for DBSCAN to generate clusters. This portion of data is then used to train the SVM along with the clusters generated by DBSCAN as output. SVM is then tested on unseen data as a predictive tool, which can work in real time to categorize data points as either normal or anomalous. This paper presents results that show the high accuracies of DBSCAN and SVM in capturing anomalies within the data for a CWS for fault detection. Thus, the maintenance plan would be focused on component condition rather than a time-based schedule by switching to an automated system to identify and predict faults within a CWS.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Comparative Analysis of Model Predictive Control and MPC-Informed Rule-Based Control for Thermal Storage Operation in Ultra-Low Temperature 4th Generation District Heating Networks
The integration of thermal storage and heat pumps in district heating networks (DHNs) can significantly enhance operational flexibility and energy efficiency; however, the practical deployment of advanced control strategies is often hindered by forecasting requirements and computational complexity. This study presents a comparative analysis of thermal storage control strategies in an ultra-low-temperature fourth-generation DHN, focusing on the development of a simplified rule-based control (RBC) explicitly informed by Model Predictive Control (MPC) behavior. The proposed methodology systematically analyzes the charging and discharging decisions of an MPC-controlled system under ideal forecasting conditions and extracts recurrent control patterns as a function of key system variables, including outdoor temperature, thermal demand, and electricity price. These patterns are translated into a set of structured time- and condition-based rules, resulting in an MPC-informed RBC that embeds predictive insights while preserving implementation simplicity and operational transparency. The approach is validated on a realistic mixed-use urban district in Denver, Colorado, USA, equipped with a centralized air-source heat pump, distributed water-to-water heat pumps, and a central thermal storage unit. Results show that the tuned RBC attains approximately 96% of ideal MPC economic performance (-27% of costs), preserves values of technical and environmental indicators (reduction only of 2-3%), and substantially reduces complexity. Sensitivity analyses further demonstrate the robustness of the RBC under varying operational conditions (i.e., ambient temperature, electricity price). Overall, the study demonstrates that MPC-informed rule-based control represents an effective trade-off between control performance and real-world applicability, enabling the integration of additional system components while maintaining simplicity, robustness, and ease of implementation.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Technical Assessment of the Application of Digital Twin and Prognostic Tools for Condition Monitoring
This report was prepared for the U.S. Nuclear Regulatory Commission (NRC) to present use cases of the application of advanced technologies toward meeting the current and future regulatory requirements for maintenance and condition monitoring of structures, systems, and components (SSCs). The advanced technologies considered in this work, collectively referred to as digital twin (DT) technologies, are advanced sensors and instrumentation, data analytics, machine learning and artificial intelligence (ML/AI), and physics-based models. The report presents two use cases of reactor coolant pumps (RCPs) and heat pipes in nuclear power plants (NPPs) with technical and regulatory considerations and opportunities in using advanced technologies for conditional monitoring. Key findings from the exploration of these considerations are as follows: - Uncertainties in sensor data and model predictions must be rigorously addressed through validation and verification processes - Regulatory compliance is paramount, necessitating data driven models to be developed in line with existing codes and standards, as well as considering potential future guidelines for advanced reactors - Explainability and transparency in ML/AI models are essential for developing operator trust and regulatory review, including methods that enhance the interpretability of complex data-driven predictions - Condition monitoring programs must be evaluated for their effectiveness in reducing maintenance-preventable function failures (MPFF) and aligning with plant performance criteria - The deployment of advanced technologies for condition monitoring could lead to a transition from periodic to continuous monitoring, thereby optimizing maintenance schedules - Collaborative efforts between industry stakeholders, regulatory bodies, and technology developers are crucial for the successful adoption of advanced technologies for condition monitoring systems in nuclear facilities In summary, the introduction of advanced technologies into condition monitoring programs represents a significant leap forward in the domain of NPP maintenance. By harnessing the capabilities of advanced sensors, data analytics, and ML/AI, NPP operators can transition from a time-based to a condition-based maintenance approach. This shift can potentially enhance the reliability and safety of critical plant components while optimizing maintenance efforts and minimizing unnecessary outages. The NRC is continuing to explore the regulatory aspects of advanced technologies as part of inservice inspection and inservice testing (ISI and IST) programs by pursuing additional research in this technical area.
22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
Software reliability through fault-avoidance and fault-tolerance
Strategies and tools for the testing, risk assessment and risk control of dependable software-based systems were developed. Part of this project consists of studies to enable the transfer of technology to industry, for example the risk management techniques for safety-concious systems. Theoretical investigations of Boolean and Relational Operator (BRO) testing strategy were conducted for condition-based testing. The Basic Graph Generation and Analysis tool (BGG) was extended to fully incorporate several variants of the BRO metric. Single- and multi-phase risk, coverage and time-based models are being developed to provide additional theoretical and empirical basis for estimation of the reliability and availability of large, highly dependable software. A model for software process and risk management was developed. The use of cause-effect graphing for software specification and validation was investigated. Lastly, advanced software fault-tolerance models were studied to provide alternatives and improvements in situations where simple software fault-tolerance strategies break down.
Vouk, Mladen A.↗
Reusable Rocket Engine Turbopump Health Management System
A health monitoring expert system software architecture has been developed to support condition-based health monitoring of rocket engines. Its first application is in the diagnosis decisions relating to the health of the high pressure oxidizer turbopump (HPOTP) of Space Shuttle Main Engine (SSME). The post test diagnostic system runs off-line, using as input the data recorded from hundreds of sensors, each running typically at rates of 25, 50, or .1 Hz. The system is invoked after a test has been completed, and produces an analysis and an organized graphical presentation of the data with important effects highlighted. The overall expert system architecture has been developed and documented so that expert modules analyzing other line replaceable units may easily be added. The architecture emphasizes modularity, reusability, and open system interfaces so that it may be used to analyze other engines as well.
Surko, Pamela↗
On-Line Modal State Monitoring of Slowly Time-Varying Structures
Monitoring the dynamic response of structures is often performed for a variety of reasons. These reasons include condition-based maintenance, health monitoring, performance improvements, and control. In many cases the data analysis that is performed is part of a repetitive decision-making process, and in these cases the development of effective on-line monitoring schemes help to speed the decision-making process and reduce the risk of erroneous decisions. This report investigates the use of spatial modal filters for tracking the dynamics of slowly time-varying linear structures. The report includes an overview of modal filter theory followed by an overview of several structural system identification methods. Included in this discussion and comparison are H-infinity, eigensystem realization, and several time-domain least squares approaches. Finally, a two-stage adaptive on-line monitoring scheme is developed and evaluated.
Johnson, Erik A.↗
Condition Monitoring of Large-Scale Facilities
This document provides a summary of the research conducted for the NASA Ames Research Center under grant NAG2-1182 (Condition-Based Monitoring of Large-Scale Facilities). The information includes copies of view graphs presented at NASA Ames in the final Workshop (held during December of 1998), as well as a copy of a technical report provided to the COTR (Dr. Anne Patterson-Hine) subsequent to the workshop. The material describes the experimental design, collection of data, and analysis results associated with monitoring the health of large-scale facilities. In addition to this material, a copy of the Pennsylvania State University Applied Research Laboratory data fusion visual programming tool kit was also provided to NASA Ames researchers.
Hall, David L.↗
Intelligent, Self-Diagnostic Thermal Protection System for Future Spacecraft
The goal of this project is to provide self-diagnostic capabilities to the thermal protection systems (TPS) of future spacecraft. Self-diagnosis is especially important in thermal protection systems (TPS), where large numbers of parts must survive extreme conditions after weeks or years in space. In-service inspections of these systems are difficult or impossible, yet their reliability must be ensured before atmospheric entry. In fact, TPS represents the greatest risk factor after propulsion for any transatmospheric mission. The concepts and much of the technology would be applicable not only to the Crew Exploration Vehicle (CEV), but also to ablative thermal protection for aerocapture and planetary exploration. Monitoring a thermal protection system on a Shuttle-sized vehicle is a daunting task: there are more than 26,000 components whose integrity must be verified with very low rates of both missed faults and false positives. The large number of monitored components precludes conventional approaches based on centralized data collection over separate wires; a distributed approach is necessary to limit the power, mass, and volume of the health monitoring system. Distributed intelligence with self-diagnosis further improves capability, scalability, robustness, and reliability of the monitoring subsystem. A distributed system of intelligent sensors can provide an assurance of the integrity of the system, diagnosis of faults, and condition-based maintenance, all with provable bounds on errors.
Hyers, Robert W.↗
Emerging technologies for V&V of ISHM software for space exploration
Systems1,2 required to exhibit high operational reliability often rely on some form of fault protection to recognize and respond to faults, preventing faults' escalation to catastrophic failures. Integrated System Health Management (ISHM) extends the functionality of fault protection to both scale to more complex systems (and systems of systems), and to maintain capability rather than just avert catastrophe. Forms of ISHM have been utilized to good effect in the maintenance phase of systems' total lifecycles (often referred to as 'condition-based mainte-nance'), but less so in a 'fault protection' role during actual operations. One of the impediments to such use lies in the challenges of verification, validation and certification of ISHM systems themselves. This paper makes the case that state-of-the-practice V&V and certification techniques will not suffice for emerging forms of ISHM systems; however, a number of maturing software engineering assurance technologies show particular promise for addressing these ISHM V&V challenges.
fault detection, isolation, and recovery↗
Microwave Blade Tip Clearance System: An Update
Newer engines use compressor bleed air and a model to close clearances open loop. Measuring clearances and closing the control loop can add additional efficiencies. Tip clearance control has been identified as a key technology for future engines Additional benefits in prognostics, NSMS, and condition-based maintenance. In the HPT for every 1 mil improvement in clearance: a) SFC decreases 0.1%; and b) EGT margin increases 1 C.
Geisheimer, Jon↗
NASA Stennis Space Center Integrated System Health Management Test Bed and Development Capabilities
Integrated System Health Management (ISHM) is a capability that focuses on determining the condition (health) of every element in a complex System (detect anomalies, diagnose causes, prognosis of future anomalies), and provide data, information, and knowledge (DIaK)-not just data-to control systems for safe and effective operation. This capability is currently done by large teams of people, primarily from ground, but needs to be embedded on-board systems to a higher degree to enable NASA's new Exploration Mission (long term travel and stay in space), while increasing safety and decreasing life cycle costs of spacecraft (vehicles; platforms; bases or outposts; and ground test, launch, and processing operations). The topics related to this capability include: 1) ISHM Related News Articles; 2) ISHM Vision For Exploration; 3) Layers Representing How ISHM is Currently Performed; 4) ISHM Testbeds & Prototypes at NASA SSC; 5) ISHM Functional Capability Level (FCL); 6) ISHM Functional Capability Level (FCL) and Technology Readiness Level (TRL); 7) Core Elements: Capabilities Needed; 8) Core Elements; 9) Open Systems Architecture for Condition-Based Maintenance (OSA-CBM); 10) Core Elements: Architecture, taxonomy, and ontology (ATO) for DIaK management; 11) Core Elements: ATO for DIaK Management; 12) ISHM Architecture Physical Implementation; 13) Core Elements: Standards; 14) Systematic Implementation; 15) Sketch of Work Phasing; 16) Interrelationship Between Traditional Avionics Systems, Time Critical ISHM and Advanced ISHM; 17) Testbeds and On-Board ISHM; 18) Testbed Requirements: RETS AND ISS; 19) Sustainable Development and Validation Process; 20) Development of on-board ISHM; 21) Taxonomy/Ontology of Object Oriented Implementation; 22) ISHM Capability on the E1 Test Stand Hydraulic System; 23) Define Relationships to Embed Intelligence; 24) Intelligent Elements Physical and Virtual; 25) ISHM Testbeds and Prototypes at SSC Current Implementations; 26) Trailer-Mounted RETS; 27) Modeling and Simulation; 28) Summary ISHM Testbed Environments; 29) Data Mining - ARC; 30) Transitioning ISHM to Support NASA Missions; 31) Feature Detection Routines; 32) Sample Features Detected in SSC Test Stand Data; and 33) Health Assessment Database (DIaK Repository).
Figueroa, Fernando↗
Hybrid Modeling Improves Health and Performance Monitoring
Scientific Monitoring Inc. was awarded a Phase I Small Business Innovation Research (SBIR) project by NASA's Dryden Flight Research Center to create a new, simplified health-monitoring approach for flight vehicles and flight equipment. The project developed a hybrid physical model concept that provided a structured approach to simplifying complex design models for use in health monitoring, allowing the output or performance of the equipment to be compared to what the design models predicted, so that deterioration or impending failure could be detected before there would be an impact on the equipment's operational capability. Based on the original modeling technology, Scientific Monitoring released I-Trend, a commercial health- and performance-monitoring software product named for its intelligent trending, diagnostics, and prognostics capabilities, as part of the company's complete ICEMS (Intelligent Condition-based Equipment Management System) suite of monitoring and advanced alerting software. I-Trend uses the hybrid physical model to better characterize the nature of health or performance alarms that result in "no fault found" false alarms. Additionally, the use of physical principles helps I-Trend identify problems sooner. I-Trend technology is currently in use in several commercial aviation programs, and the U.S. Air Force recently tapped Scientific Monitoring to develop next-generation engine health-management software for monitoring its fleet of jet engines. Scientific Monitoring has continued the original NASA work, this time under a Phase III SBIR contract with a joint NASA-Pratt & Whitney aviation security program on propulsion-controlled aircraft under missile-damaged aircraft conditions.
Source record↗
Monitoring System for Storm Readiness and Recovery of Test Facilities: Integrated System Health Management (ISHM) Approach
Severe weather events are likely occurrences on the Mississippi Gulf Coast. It is important to rapidly diagnose and mitigate the effects of storms on Stennis Space Center's rocket engine test complex to avoid delays to critical test article programs, reduce costs, and maintain safety. An Integrated Systems Health Management (ISHM) approach and technologies are employed to integrate environmental (weather) monitoring, structural modeling, and the suite of available facility instrumentation to provide information for readiness before storms, rapid initial damage assessment to guide mitigation planning, and then support on-going assurance as repairs are effected and finally support recertification. The system is denominated Katrina Storm Monitoring System (KStorMS). Integrated Systems Health Management (ISHM) describes a comprehensive set of capabilities that provide insight into the behavior the health of a system. Knowing the status of a system allows decision makers to effectively plan and execute their mission. For example, early insight into component degradation and impending failures provides more time to develop work around strategies and more effectively plan for maintenance. Failures of system elements generally occur over time. Information extracted from sensor data, combined with system-wide knowledge bases and methods for information extraction and fusion, inference, and decision making, can be used to detect incipient failures. If failures do occur, it is critical to detect and isolate them, and suggest an appropriate course of action. ISHM enables determining the condition (health) of every element in a complex system-of-systems or SoS (detect anomalies, diagnose causes, predict future anomalies), and provide data, information, and knowledge (DIaK) to control systems for safe and effective operation. ISHM capability is achieved by using a wide range of technologies that enable anomaly detection, diagnostics, prognostics, and advise for control: (1) anomaly detection algorithms and strategies, (2) fusion of DIaK for anomaly detection (model-based, numerical, statistical, empirical, expert-based, qualitative, etc.), (3) diagnostics/prognostics strategies and methods, (4) user interface, (5) advanced control strategies, (6) integration architectures/frameworks, (7) embedding of intelligence. Many of these technologies are mature, and they are being used in the KStorMS. The paper will describe the design, implementation, and operation of the KStorMS; and discuss further evolution to support other needs such as condition-based maintenance (CBM).
Figueroa, Fernando↗
Automated Vectorization of Decision-Based Algorithms
Virtually all existing vectorization algorithms are designed to only analyze the numeric properties of an algorithm and distribute those elements across multiple processors. This advances the state of the practice because it is the only known system, at the time of this reporting, that takes high-level statements and analyzes them for their decision properties and converts them to a form that allows them to automatically be executed in parallel. The software takes a high-level source program that describes a complex decision- based condition and rewrites it as a disjunctive set of component Boolean relations that can then be executed in parallel. This is important because parallel architectures are becoming more commonplace in conventional systems and they have always been present in NASA flight systems. This technology allows one to take existing condition-based code and automatically vectorize it so it naturally decomposes across parallel architectures.
James, Mark↗
Prognostics for Microgrid Components
Prognostics is the science of predicting future performance and potential failures based on targeted condition monitoring. Moving away from the traditional reliability centric view, prognostics aims at detecting and quantifying the time to impending failures. This advance warning provides the opportunity to take actions that can preserve uptime, reduce cost of damage, or extend the life of the component. The talk will focus on the concepts and basics of prognostics from the viewpoint of condition-based systems health management. Differences with other techniques used in systems health management and philosophies of prognostics used in other domains will be shown. Examples relevant to micro grid systems and subsystems will be used to illustrate various types of prediction scenarios and the resources it take to set up a desired prognostic system. Specifically, the implementation results for power storage and power semiconductor components will demonstrate specific solution approaches of prognostics. The role of constituent elements of prognostics, such as model, prediction algorithms, failure threshold, run-to-failure data, requirements and specifications, and post-prognostic reasoning will be explained. A discussion on performance evaluation and performance metrics will conclude the technical discussion followed by general comments on open research problems and challenges in prognostics.
Saxena, Abhinav↗
Model-Based Diagnosis and Prognosis of a Water Recycling System
A water recycling system (WRS) deployed at NASA Ames Research Center s Sustainability Base (an energy efficient office building that integrates some novel technologies developed for space applications) will serve as a testbed for long duration testing of next generation spacecraft water recycling systems for future human spaceflight missions. This system cleans graywater (waste water collected from sinks and showers) and recycles it into clean water. Like all engineered systems, the WRS is prone to standard degradation due to regular use, as well as other faults. Diagnostic and prognostic applications will be deployed on the WRS to ensure its safe, efficient, and correct operation. The diagnostic and prognostic results can be used to enable condition-based maintenance to avoid unplanned outages, and perhaps extend the useful life of the WRS. Diagnosis involves detecting when a fault occurs, isolating the root cause of the fault, and identifying the extent of damage. Prognosis involves predicting when the system will reach its end of life irrespective of whether an abnormal condition is present or not. In this paper, first, we develop a physics model of both nominal and faulty system behavior of the WRS. Then, we apply an integrated model-based diagnosis and prognosis framework to the simulation model of the WRS for several different fault scenarios to detect, isolate, and identify faults, and predict the end of life in each fault scenario, and present the experimental results.
Roychoudhury, Indranil↗