Results for “maintenance engineering” — Page 14

NASA NTRS1985

Orbital transfer vehicle engine integration study

Industry studies were undertaken to establish the technology base for an advanced engine for Orbital Transfer Vehicles for mid-1990s IOC. This paper presents the results of a study conducted by General Dynamics Convair Division, under contract to Aerojet TechSystems Company for NASA-LeRC, to define requirements, interface conditions, and operational design criteria for new LO2/LH2 propulsion systems applicable to future Orbit Transfer Vehicles, and to assess the impacts of space basing, man rating, and low-g transfer on propulsion system design requirements. The primary study emphasis was to determine what the OTV engine thrust level should be, how many engines are required on the OTV, and how the OTV engine should be designed. This was accomplished by evaluating planned OTV missions and concepts to determine the requirements for the OTV propulsion system, conducting tradeoffs and comparisons to optimize OTV capability, and evaluating reliability and maintenance to determine the recommended OTV engine design for future development.

Ketchum, W. J.↗

NASA NTRS1984

Orbital transfer vehicle engine integration study

NASA-LeRC is sponsoring industry studies to establish the technology base for an advanced engine for orbital transfer vehicles for mid-1990s IOC. Engine contractors are being assisted by vehicle contractors to define the requirements, interface conditions, and operational design criteria for new LO2-LH2 propulsion systems applicable to future orbit transfer vehicles and to assess the impacts on space basing, man rating, and low-G transfer missions on propulsion system design requirements. The results of a study is presented. The primary study emphasis was to determine what the OTV engine thrust level should be, how many engines are required on the OTV, and how the OTV engine should be designed. This was accomplished by evaluating planned OTV missions and concepts to determine the requirements for the OTV propulsion system, conducting tradeoffs and comparisons to optimize OTV capability, and evaluating reliability and maintenance to determine the recommended OTV engine design for future development.

Ketchum, W. J.↗

DOE OSTI2025

Risk-informed Graded Approach for Reliability and Performance Assessment of Machine Learning and Artificial Intelligence for Advanced Condition Monitoring Techniques

With the shift away from time-based maintenance and toward condition-based maintenance, and to reduce overall maintenance costs, there has been an upsurge in the usage and development of advanced condition monitoring (ACM) techniques for real-time monitoring of nuclear power plant (NPP) components. ACM is particularly useful in the development of digital twins, which are designed to predict the failure or degradation of plant components. Successful implementation of ACM requires an assessment to inform the development of a risk-informed approach to evaluate the use of ACM to meet Nuclear Regulatory Committee (NRC) regulations for in-service testing (IST) programs. This includes the monitoring and diagnostics of reactor components and systems in current, new, and advanced reactors. A key component in ACM is the usage of machine learning (ML) and artificial intelligence (AI) algorithms that can employ real-time data from instrumentation and sensors to detect and predict reactor component degradations. Such predictive capabilities enable early detection of component degradation so as to help plant personnel plan and execute necessary maintenance. For successful implementation of ML/AI in ACM such that regulatory requirements are met, a risk-informed graded approach is needed to assess the reliability and performance of ML/AI for ACM. The American Society for Mechanical Engineers (ASME) developed their Operations and Maintenance (O&M) Code to provide guidance on safe, reliable O&M of NPPs. The IST section of the O&M Code specifically establishes requirements for IST and examination to gauge operational readiness of components in water-cooled NPPs. This paper presents a state-of-the-art review of how reliability and risk assessment can be integrated with ACM to assess component performance by non-nuclear industries. This is followed by different methodologies and approaches for conducting performance and reliability assessments so as to meet IST requirements for NPP components.

97 - MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Risk-informed Graded Approach for Reliability and Performance Assessment for Advanced Condition Monitoring Techniques

With the shift away from time-based maintenance and toward condition-based maintenance, and to reduce overall maintenance costs, there has been an upsurge in the usage and development of advanced condition monitoring (ACM) techniques for real-time monitoring of nuclear power plant (NPP) components. ACM is particularly useful in the development of digital twins, which are designed to predict the failure or degradation of plant components. Successful implementation of ACM requires an assessment to inform the development of a risk-informed approach to evaluate the use of ACM to meet Nuclear Regulatory Committee (NRC) regulations for in-service testing (IST) programs. This includes the monitoring and diagnostics of reactor components and systems in current, new, and advanced reactors. A key component in ACM is the usage of machine learning (ML) and artificial intelligence (AI) algorithms that can employ real-time data from instrumentation and sensors to detect and predict reactor component degradations. Such predictive capabilities enable early detection of component degradation so as to help plant personnel plan and execute necessary maintenance. For successful implementation of ML/AI in ACM such that regulatory requirements are met, a risk-informed graded approach is needed to assess the reliability and performance of ML/AI for ACM. The American Society for Mechanical Engineers (ASME) developed their Operations and Maintenance (O&M) Code to provide guidance on safe, reliable O&M of NPPs. The IST section of the O&M Code specifically establishes requirements for IST and examination to gauge operational readiness of components in water-cooled NPPs. This paper presents a state-of-the-art review of how reliability and risk assessment can be integrated with ACM to assess component performance by non-nuclear industries. This is followed by different methodologies and approaches for conducting performance and reliability assessments so as to meet IST requirements for NPP components.

99 - GENERAL AND MISCELLANEOUS↗

NASA NTRS2013

Engineered Surfaces for Mitigation of Insect Residue Adhesion

Maintenance of laminar flow under operational flight conditions is being investigated under NASA s Environmentally Responsible Aviation (ERA) Program. Among the challenges with natural laminar flow is the accretion of residues from insect impacts incurred during takeoff or landing. Depending on air speed, temperature, and wing structure, the critical residue height for laminar flow disruption can be as low as 4 microns near the leading edge. In this study, engineered surfaces designed to minimize insect residue adhesion were examined. The coatings studied included chemical compositions containing functional groups typically associated with abhesive (non-stick) surfaces. To reduce surface contact by liquids and enhance abhesion, the engineered surfaces consisted of these coatings doped with particulate additives to generate random surface topography, as well as coatings applied to laser ablated surfaces having precision patterned topographies. Performance evaluation of these surfaces included contact angle goniometry of pristine coatings and profilometry of surfaces after insect impacts were incurred in laboratory scale tests, wind tunnel tests and flight tests. The results illustrate the complexity of designing antifouling surfaces for effective insect contamination mitigation under dynamic conditions and suggest that superhydrophobic surfaces may not be the most effective solution for preventing insect contamination on aircraft wing leading edges.

Siochi, Emilie J.↗

DOE OSTI2023

Chapter 14 - Reliability of Wind Turbines

The global wind energy industry has grown at a fast pace during the past half-decade. Advancements from design and manufacturing to operation and maintenance have led to reduced capital and maintenance costs, which make wind power an indispensable source for a comprehensive solution to global electricity needs. Once wind turbines are installed, the opportunity to lower wind power costs is mainly through improved operation and maintenance practices. Modern wind turbines are equipped with tens or hundreds of measurement channels and are generating an abundance of data, with lot of efforts being put into data analysis by both the research community and the industry. One type of analysis is through the exploration of reliability engineering methods based on readily available data or maintenance records collected at typical wind power plants. If adopted and conducted appropriately, these analyses can quickly save operation and maintenance costs in a potentially impactful manner. The wind industry has adopted this discipline more broadly in recent years. This chapter discusses wind turbine reliability by highlighting the methodology of reliability engineering life data analysis. It first briefly discusses the fundamentals of wind turbine reliability and the current industry status. Then, the reliability engineering method for life analysis, including data collection, model development, and forecasting, is presented in detail and illustrated through two case studies. The chapter concludes with some remarks on potential opportunities to improve wind turbine reliability. An owner and operator's perspective is taken and mechanical components are used to exemplify the potential benefits of reliability engineering analysis to improve wind turbine reliability and availability.

database↗

NASA NTRS2004

Upgrades at the Propulsion Systems Lab (PSL)

The Propulsion Systems Lab (PSL) does ground testing on full size air breathing engines. These engines range from those on commercial airplanes to fighter jets. At the PSL, engineers receive test requirements from customers and put together the necessary instrumentation, data systems, power requirements, electrical control valves, and engine controls. The engineers are also responsible for facility maintenance, repairs and upgrades. There are four major sections at the PSL; the Test floor, the Data room, the Control room and, the WDPF room. On the test floor are two test cells, cell #3 and cell #4. It is within these cells that the actual engine resides for ground testing. The cells, once sealed and taken up to altitude, are capable of reaching engine inlet temperatures of 1000 F to -90 F, and various atmospheric pressures. The engine, when operational, takes in air and gives out exhaust of up to 2000 F. The exhaust is led to another section of the cell where it is cooled to 150 F before finally redirected to the appropriate disposer. Temperature and pressure transducers detect the conditions within the cell and transmit them to the data room where the results are captured, processed, analyzed, and translated to a more comprehensive language. This is made possible with the aid of several programmable logic controllers (PLCs) and instrumentation and control systems. The translated data is then sent, via the LAN, to the control room where the results can be viewed on monitors by the engineers and customers. From the control room, the test cell conditions can be changed whenever desired. During tests, a lot takes place in the facility. The WDPF control system monitors and controls all facility parameters. This summer, I will assist the engineers; on an upgrade to the facility's distributed control and dynamic data system, in preparation for an engine test that will begin in September, the installation of control systems and various miscellaneous projects around the PSL.

Audu, Abdullahi M.↗

NASA NTRS1971

Crew interface specification development study for in-flight maintenance and stowage functions

The need and potential solutions for an orderly systems engineering approach to the definition, management and documentation requirements for in-flight maintenance, assembly, servicing, and stowage process activities of the flight crews of future spacecraft were investigated. These processes were analyzed and described using a new technique (mass/function flow diagramming), developed during the study, to give visibility to crew functions and supporting requirements, including data products. This technique is usable by NASA for specification baselines and can assist the designer in identifying both upper and lower level requirements associated with these processes. These diagrams provide increased visibility into the relationships between functions and related equipments being utilized and managed and can serve as a common communicating vehicle between the designer, program management, and the operational planner. The information and data product requirements to support the above processes were identified along with optimum formats and contents of these products. The resulting data product concepts are presented to support these in-flight maintenance and stowage processes.

Carl, J. G.↗

DOE OSTI2025

Computational materials reliability assessment of hydrogen fueled gas turbine power generation engines

The use of blended fuel sources in land based gas turbine engines drives variations in the resulting operational profile (temperatures and pressures) which can impact engine reliability. Furthermore, variability in the manufacture of components affects the resulting microstructure which directly impacts material performance and reliability. Currently, data-driven models are typically used for maintaining and inspecting fleets of engines. Without explicitly capturing material and operational sources of variability conservatism must be used in developing component-level reliability models. Therefore, there exists an opportunity to use information from materials-scale physics models to better inform reliability modeling and reduce conservatism; the impact is more cost-efficient operation and maintenance of current and future fleets. Specifically, this work establishes a computational framework for evaluating the probabilistic high temperature creep performance of hot-section Ni-based superalloys where uncertainty comes from both microstructural and operational variability. A novel high-fidelity physics model which phenomenologically captures grain-boundary sensitive phenomena has been established. A probabilistic calibration procedure was used to calibrate the model and capture uncertainty in the parameterized model coefficients. A design of experiments methodology was established for identifying informative microstructural digital representations for suitable for forward model evaluation. Results show that training a machine-learning surrogate using this design criteria outperforms random selection of microstructural representations. Finally, two surrogate models were developed: (1) a deterministic surrogate model which predicts the local field response given microstructure, constitutive model parameters, and operating conditions (stress, temperature) and (2) a probabilistic model, where uncertainty comes from constitutive law uncertainty, built using denoising diffusion probabilistic models which samples responses given (1) microstructure and (2) operating conditions. These surrogate models enable partner Siemens Energy to rapidly perform UQ analysis specific to creep deformation across a range of microstructures and operating conditions. The impact is that these ML and physics codes can be used to establish more advanced reliability models for the inspection, servicing, and maintenance of land based gas turbine engines.

36 MATERIALS SCIENCE↗

NASA NTRS2004

Probabilistic Study Conducted on Sensor-Based Engine Life Calculation

Turbine engine life management is a very complicated process to ensure the safe operation of an engine subjected to complex usage. The challenge of life management is to find a reasonable compromise between the safe operation and the maximum usage of critical parts to reduce maintenance costs. The commonly used "cycle count" approach does not take the engine operation conditions into account, and it oversimplifies the calculation of the life usage. Because of the shortcomings, many engine components are regularly pulled for maintenance before their usable life is over. And, if an engine has been running regularly under more severe conditions, components might not be taken out of service before they exceed their designed risk of failure. The NASA Glenn Research Center and its industrial and academic partners have been using measurable parameters to improve engine life estimation. This study was based on the Monte Carlo simulation of 5000 typical flights under various operating conditions. First a closed-loop engine model was developed to simulate the engine operation across the mission profile and a thermomechanical fatigue (TMF) damage model was used to calculate the actual damage during takeoff, where the maximum TMF accumulates. Next, a Weibull distribution was used to estimate the implied probability of failure for a given accumulated cycle count. Monte Carlo simulations were then employed to find the profiles of the TMF damage under different operating assumptions including parameter uncertainties. Finally, probabilities of failure for different operating conditions were analyzed to demonstrate the importance of a sensor-based damage calculation in order to better manage the risk of failure and on-wing life.

Guo, Ten-Huei↗

DOE OSTI2021

Climate change deniers, hippies, and preppers. Oh my!: Unpacking engineering student perceptions of renewable energy technology adoption in the United States

Engineers play a key role in the formation, operation, and maintenance of large socio-technical systems. Enmeshed in these practices of engineering are shared perceptions and visions of how society should be ordered, and what role of engineers should play. These value systems and how they shape the perception of who and where alternative energy belongs will shape who does or does not have the opportunity to participate in these alternative visions of energy. Drawing on engineering studies and dialectology research this study examines how a group of engineering students engaged in learning about renewable energy systems perceive the kinds of people in the United States who would or would not adopt alternative energy. Rather than see adoption/non-adoption as a purely “technical” matter, students brought their own perceptions of regional, social, and political differences to characterize the potential acceptability of each technology. Certain regions of the United States, despite their technical potential based on government and industry sources, are cast as too culturally backward and resistant to change to embrace new energy sources. In conclusion, these insights elucidate the importance of 'engineers' value systems as they continue to play a significant role in shaping the development of alternative energy technologies and markets.

Adoption↗

NASA NTRS1994

Using Dedal to share and reuse distributed engineering design information

The overall goal of the project is to facilitate the reuse of previous design experience for the maintenance, repair and redesign of artifacts in the electromechanical engineering domain. An engineering team creates information in the form of meeting summaries, project memos, progress reports, engineering notes, spreadsheet calculations and CAD drawings. Design information captured in these media is difficult to reuse because the way design concepts are referred to evolve over the life of a project and because decisions, requirements and structure are interrelated but rarely explicitly linked. Based on protocol analysis of the information seeking behavior of designer's, we defined a language to describe the content and the form of design records and implemented this language in Dedal, a tool for indexing, modeling and retrieving design information. We first describe the approach to indexing and retrieval in Dedal. Next we describe ongoing work in extending Dedal's capabilities to a distributed environment by integrating it with World Wide Web. This will enable members of a design team who are not co-located to share and reuse information.

Baya, Vinod↗

DOE OSTI2022

Hydrogen for Maritime Applications

The maritime industry is investigating a number of fuel options for reducing emissions, including liquefied natural gas (LNG), biofuels, and electrical drive systems powered by batteries and/or hydrogen-fueled fuel cells. Hydrogen-fueled ships offer the potential to significantly reduce, if not eliminate, regulated and unregulated pollutants in maritime applications. Argonne National Laboratory conducted preliminary comparisons of the total cost of ownership (TCO) of several classes of ships to determine how fuel cell technology compares to the current diesel technology, what advancements are needed for hydrogen fuel cell technology to be competitive in the future, and what applications may be appropriate for introducing fuel cells into the maritime industry. These studies included feeder container ships, harbor tugboats, river pushboats, and auto/passenger ferries. For this study, TCO was defined to include the cost of fuel, propulsion system, and fuel storage system, the levelized cost of propulsion/auxiliary engines, and the cost of annual maintenance and consumables. It did not include the cost of the vessel frame or other components, aside from the propulsion system, that the fuel cell and diesel ships have in common. A 10% internal rate of return (IRR) was applied to the initial capital investment and an installation cost factor of 20% was applied to the capital cost. The capital cost of each component (e.g., engine, fuel tank, motor, etc.) was amortized over a period of 20 years, except for the fuel cell system, which was amortized over 6 or 10 years depending on ship class. The initial comparisons for container ships indicate that fuel costs are by far the dominant contributor to the TCO. With the current low cost of low-sulfur marine gasoil (LSMGO) and relatively high cost of hydrogen, it is difficult for hydrogen to compete with LSMGO in container ship applications. The large energy demand for container ships also favors the use of the higher volumetric energy density LSMGO fuel, especially for longer voyages. The space required to store enough hydrogen for the same journey is larger than that needed to store diesel fuels and can reduce the available cargo carrying and revenue generating space available on the ship.

08 HYDROGEN↗

NASA NTRS1979

Near-term hybrid vehicle program, phase 1. Appendix D: Sensitivity analysis resport

Parametric analyses, using a hybrid vehicle synthesis and economics program (HYVELD) are described investigating the sensitivity of hybrid vehicle cost, fuel usage, utility, and marketability to changes in travel statistics, energy costs, vehicle lifetime and maintenance, owner use patterns, internal combustion engine (ICE) reference vehicle fuel economy, and drive-line component costs and type. The lowest initial cost of the hybrid vehicle would be $1200 to $1500 higher than that of the conventional vehicle. For nominal energy costs ($1.00/gal for gasoline and 4.2 cents/kWh for electricity), the ownership cost of the hybrid vehicle is projected to be 0.5 to 1.0 cents/mi less than the conventional ICE vehicle. To attain this ownership cost differential, the lifetime of the hybrid vehicle must be extended to 12 years and its maintenance cost reduced by 25 percent compared with the conventional vehicle. The ownership cost advantage of the hybrid vehicle increases rapidly as the price of fuel increases from $1 to $2/gal.

Source record↗

DOE OSTI2025

Artificial Intelligence and Digital Engineering as Enablers for System Engineering in the Energy Sector

Systems engineering is of utmost importance for the success of high-cost, high-complexity megaprojects, which are common in the energy sector. However, the traditional document-centric systems engineering approach tends to be labor-intensive and time-consuming, which has inhibited its full adoption despite proven metrics on its return on investment. However, with the modern approach of digital engineering and technological advancements in artificial intelligence (AI) technologies, the barriers to systems engineering adoption can finally be broken. This paper goes through the systems engineering V-model for lifecycle management and assesses the current state of implementation of digital engineering (especially, mod-el-based systems engineering, digital twins, and digital threads) and AI for each step. It was observed that a combination of digital engineering and AI is being used across different industries to accelerate and optimize systems engineering processes such as concept development, requirements management, architecture definition, system development, verification and validation, operations, and maintenance. Specifically in the energy sector, AI-augmented digital engineering has shown initial potential in accelerated development and deployment, performance optimization, anomaly detection, predictive maintenance, and configuration management. However, challenges remain in integrating DE and AI into an end-to-end system lifecycle management ecosystem safely and reliably. Addressing these challenges and continuously developing impactful tools will enable fast, efficient, and high-frequency deployment of power generation capabilities to keep up with the world’s energy demands and build energy security.

42 - ENGINEERING↗

DOE OSTI2025

Artificial Intelligence and Digital Engineering as Enablers for Systems Engineering in the Energy Sector

Systems engineering is of utmost importance for the success of high-cost, high-complexity megaprojects, which are common in the energy sector. However, the traditional document-centric systems engineering approach tends to be labor-intensive and time-consuming, which has inhibited its full adoption despite proven metrics on its return on investment. However, with the modern approach of digital engineering and technological advancements in artificial intelligence (AI) technologies, the barriers to systems engineering adoption can finally be broken. This paper goes through the systems engineering V-model for lifecycle management and assesses the current state of implementation of digital engineering (especially, mod-el-based systems engineering, digital twins, and digital threads) and AI for each step. It was observed that a combination of digital engineering and AI is being used across different industries to accelerate and optimize systems engineering processes such as concept development, requirements management, architecture definition, system development, verification and validation, operations, and maintenance. Specifically in the energy sector, AI-augmented digital engineering has shown initial potential in accelerated development and deployment, performance optimization, anomaly detection, predictive maintenance, and configuration management. However, challenges remain in integrating DE and AI into an end-to-end system lifecycle management ecosystem safely and reliably. Addressing these challenges and continuously developing impactful tools will enable fast, efficient, and high-frequency deployment of power generation capabilities to keep up with the world?s energy demands and build energy security.

42 - ENGINEERING↗

NASA NTRS2001

Segment Alignment Maintenance System for the Hobby-Eberly Telescope

NASA's Marshall Space Flight Center, in collaboration with Blue Line Engineering of Colorado Springs, Colorado, is developing a Segment Alignment Maintenance System (SAMS) for McDonald Observatory's Hobby-Eberly Telescope (HET). The SAMS shall sense motions of the 91 primary mirror segments and send corrections to HET's primary mirror controller as the mirror segments misalign due to thermo -elastic deformations of the mirror support structure. The SAMS consists of inductive edge sensors. All measurements are sent to the SAMS computer where mirror motion corrections are calculated. In October 2000, a prototype SAMS was installed on a seven-segment cluster of the HET. Subsequent testing has shown that the SAMS concept and architecture are a viable practical approach to maintaining HET's primary mirror figure, or the figure of any large segmented telescope. This paper gives a functional description of the SAMS sub-array components and presents test data to characterize the performance of the subarray SAMS.

Rakoczy, John↗

DOE OSTI2023

Finding of Effect, And Mitigation Documentation for Building 23-620, Mercury, Area 23, Nevada National Security Site, Nye County, Nevada

The U.S. Department of Energy (DOE), National Nuclear Security Administration Nevada Field Office (NNSA/NFO) plans to demolish Building 23-620 in the town of Mercury (Nevada State Historic Preservation Office [SHPO] Resource No. B15283), which is on the Nevada National Security Site (NNSS) in Nye County, Nevada (see Figure 1). The purpose of the undertaking is related to the modernization of Mercury for future mission needs. The NNSA/NFO will implement this undertaking in accordance with the Programmatic Agreement between the National Nuclear Security Administration Nevada Field Office and the Nevada State Historic Preservation Officer Regarding Modernization and Operational Maintenance of the Nevada National Security Site, at Mercury in Nye County, Nevada, hereafter referred to as the Mercury PA. Building 23-620 was built in 1968 as office space for the Los Alamos Scientific Laboratory (LASL), who worked on the design and engineering of nuclear weapons. In the 1990s, it became a maintenance facility for Reynolds Electrical & Engineering Company (REECo), and eventually, it became the Real Estate Services building in 2004. The town of Mercury and the immediate surrounding area have been formally determined eligible for listing in the National Register of Historic Places (National Register, NRHP) as the Mercury Historic District (MHD, SHPO Resource No. D230) under Criteria A and C for its importance in supporting nuclear testing and scientific research from 1951 through 1992. Building 23-620 was identified as a contributing element to the MHD in a 2018 architectural survey of the district (Reno et al.) and recorded on a Nevada Architectural Resource Assessment (ARA) form (Reno et al. 2017). Building 23-620 was also identified in Appendix C of the Mercury PA as a Category I contributing element, indicating that it might be individually eligible for the NRHP. It is a historic property for the purposes of compliance with Section 106 of the National Historic Preservation Act (NHPA) and subject to the stipulations of the Mercury PA. Mitigation Report: The purpose of this letter report is to submit documentation related to the mitigation of the demolition of Building 23-620 (Nevada State Historic Preservation Office [SHPO] Resource No. B15283) in the Mercury Historic District (MHD, SHPO Resource No. D230). This submission is intended to comply with the stipulations in the Programmatic Agreement between the National Nuclear Security Administration Nevada Field Office and the Nevada State Historic Preservation Officer Regarding Modernization and Operational Maintenance of the Nevada National Security Site, at Mercury in Nye County, Nevada, hereafter referred to as the Mercury PA.

54 ENVIRONMENTAL SCIENCES↗