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All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Development and implementation of an in-situ cable condition monitoring method for nuclear power plants - 130

The sustainability of the existing fleet of nuclear power reactors depends on utilities' ability to manage the aging of key components that cannot easily or economically be replaced or upgraded. Cables, metals, and concrete structures are among the major and key components that the industry and government are working on to ensure the long term reliability and safety of nuclear plants. To ensure that these key components continue to meet their performance requirements, new testing and condition monitoring technologies must be developed that are capable of identifying and quantifying degradation in these materials. The work presented in this paper focuses on the development and implementation of an in-situ condition monitoring method for nuclear power plant cables. This cable condition monitoring method is based on the frequency domain reflectometry (FDR) technique, which is a non-destructive in-situ electrical test that uses the principle of transmission line theory to locate and quantify impedance changes in a cable circuit. Through extensive research, development, and validation, the FDR test technique has been adapted as a cable condition monitoring method that trends with increasing cable degradation. In addition, the FDR data has been correlated to the industry standard elongation at break (EAB) test to quantify the degree of localized degradation in nuclear plant cable insulation material caused by long term exposure to high temperatures and radiation. By correlating FDR to EAB, the aging condition of cables routed through harsh environments can be better understood in relation to its ability to perform its intended function. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Economic Analysis of Condition-Monitoring-Based Predictive Maintenance in Power Plants under Market Elasticity

Condition-monitoring-based predictive maintenance can increase the power plant availability by preventing forced outages. However, the actual on-stream time depends on market elasticity and dynamics, which are affected by cost and penetration of other power generation technologies. This paper develops a systematic approach for the economic analysis of investment in condition monitoring technologies with due consideration of market elasticity. Focus is on corrosion monitoring in coal-fired power plants (CFFPs) since corrosion in high-temperature coal-fired boilers is a leading cause of equipment failure. Investment in sensor networks for measuring corrosion and operating conditions like metal temperature and concentrations of O 2 and SO 2 is investigated. The unscented Kalman filter is used to estimate corrosion in the waterwall section of the boiler under multiple sensor networks. Electricity produced by CFPPs in the future in the U.S. due to changes in availability under market elasticity is studied. Sensitivity of the incremental net present value to factors like the number, type, and cost of sensors is analyzed.

Electrochemistry↗
NASA NTRS1991

Advanced optical condition monitoring

The application of Advanced Optical Condition Monitoring to optical leak detection and plume spectrometry is discussed. The development of these selected sensors for propulsion system monitoring is addressed.

Cross, G.↗
NASA NTRS1994

Aspects of model-based rocket engine condition monitoring and control

A rigorous propulsion system modelling method suitable for control and condition monitoring purposes is developed. Previously developed control oriented methods yielding nominal models for gaseous medium propulsion systems are extended to include both nominal and anomalous models for liquid mediums in the following two ways. First, thermodynamic and fluid dynamic properties for liquids such as liquid hydrogen are incorporated into the governing equations. Second, anomalous conditions are captured in ways compatible with existing system theoretic design tools so that anomalous models can be constructed. Control and condition monitoring based methods are seen as an improvement over some existing modelling methods because such methods typically do not rigorously lead to low order models nor do they provide a means for capturing anomalous conditions. Applications to the nominal SSME HPFP and degraded HPFP serve to illustrate the approach.

Karr, Gerald R.↗
DOE OSTI2023

Condition monitoring of permanent magnet AC machines for all-electric transportation systems: State of the art

The current state of the art on emerging and efficient techniques for condition monitoring of permanent magnet (PM) alternating-current (AC) machines deployed in electric vehicle (EV) applications is presented. The discussion includes the most common and specific types of faults in PM motors, such as rotor demagnetisation and stator inter-turn faults, respectively. Fault indicators, such as voltage (v s ) and current (i s ) signals and machine signatures based on motor back electromotive force (EMF) (E B ) and magnetic flux (φ), are taken into account as a measuring quantity in diagnosing motor faults. Other signatures, including thermal analysis, acoustic noise, and vibrations, are also illustrated as some of the emerging techniques in estimating the performance of EV motors while under operations. In addition, various fault modelling methods, condition monitoring techniques, and comprehensive approaches applied in diagnosing the effect of machine faults during its incipient stages are illustrated. Since most of the fault diagnostic techniques discussed here include only machine-based quantities as fault indices/indicators, the provided solutions are therefore found to be more reliable and accurate for diagnosing the motor faults. This comprehensive review study is inclusive of the existing fault diagnostic techniques, which are currently employed in industrial and commercial practices, in addition to the new methodologies proposed by the authors. All the given condition monitoring schemes therefore seem significantly vital in estimating the state of health of PM AC machines while under operation in all-electric transportation systems.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1987

Noncontacting measurement technologies for space propulsion condition monitoring

This paper describes four noncontacting measurement technologies that can be used in a turbopump condition monitoring system. The isotope wear analyzer, fiberoptic deflectometer, brushless torque-meter, and fiberoptic pyrometer can be used to monitor component wear, bearing degradation, instantaneous shaft torque, and turbine blade cracking, respectively. A complete turbopump condition monitoring system including these four technologies could predict remaining component life, thus reducing engine operating costs and increasing reliability.

Randall, M. R.↗
NASA NTRSDate not supplied

Assessment of ProgPy - An Open-Source Condition Monitoring and Diagnostics Tool

Traditional maintenance programs, such as corrective and preventive strategies, may lead to high costs and operational inefficiencies. Condition Monitoring and Diagnostics (CM&D) aims to improve these maintenance strategies by enabling timely insights into equipment health and performance. However, implementation of CM&D can be challenging without a robust framework that manages data efficiently, supports interoperability and simplifies integration. To address these challenges ProgPy, an open-source Python-based prognostics tool developed by NASA Ames Research Center, offers a structured solution for broader Prognostics and Health Management (PHM) applications. Ongoing research is assessing the feasibility of implementing ProgPy as a Condition Monitoring and Diagnostics (CM&D) solution by comparing its framework to the guidelines for open CM&D systems recommended in the ISO 13374-2 standard. This evaluation aims to highlight ProgPy’s strengths and identify opportunities for improvement, thereby, contributing to its advancement as an effective tool for Prognostics and Health Management (PHM). This paper presents the results of an initial assessment of the ProgPy toolbox through a gearbox case study using open-source datasets.

Condition-Monitoring, Diagnostics, Failure, Gearbo↗
DOE OSTI2019

Condition Monitoring of Wind Turbine Planetary Gearboxes Under Different Operating Conditions

Digitally enhanced services for wind power could reduce Operations and Maintenance (O&M) costs as well as the Levelised Cost Of Energy (LCOE). Therefore, there is a continuous need for advanced monitoring techniques which can exploit the opportunities of Internet of Things (IoT) and Big Data Analytics, revolutionizing the future of the energy sector. The heart of wind turbines is a rather complex epicyclic gearbox. Among others, extremely critical gearbox components which are often responsible for machinery stops are the rolling element bearings. The vibration signatures of bearings are rather weak compared to other components, such as gears, and as a result an extended number of signal processing techniques and tools have been proposed during the last decades, focusing towards accurate, early, and on time bearing fault detection with limited false alarms and missed detections. Envelope Analysis is one of the most important methodologies, where an envelope of the vibration signal is estimated usually after filtering around a frequency band excited by impacts due to the bearing faults. Different tools, such as Kurtogram, have been proposed in order to accurately select the optimum filter parameters (center frequency and bandwidth). Cyclic Spectral Correlation and Cyclic Spectral Coherence, based on Cyclostationary Analysis, have been proved as very powerful tools for condition monitoring. The monitoring techniques seem to have reached a mature level in case a machinery operates under steady speed and load. On the other hand, in case the operating conditions change, it is still unclear whether the change of the monitoring indicators is due to the change of the health of the machinery or due to the change of the operating parameters. Recently, the authors have proposed a new tool called IESFOgram, which is based on Cyclic Spectral Coherence and can automatically select the filtering band. Furthermore, the Cyclic Spectral Coherence is integrated along the selected frequency band leading to an Improved Envelope Spectrum. In this paper, the performance of the tool is evaluated and further extended on cases operating under different speeds and different loads. The effectiveness of the methodology is tested and validated on the National Renewable Energy Laboratory (NREL) wind turbine gearbox vibration condition monitoring benchmarking data set which includes various faults with different levels of diagnostic complexity as well as various speed and load operating conditions.

17 WIND ENERGY↗
DOE OSTI2015

Submerged Medium Voltage Cable Systems at Nuclear Power Plants: A Review of Research Efforts Relevant to Aging Mechanisms and Condition Monitoring

In a submerged environment, power cables may experience accelerated insulation degradation due to water-related aging mechanisms. Direct contact with water or moisture intrusion in the cable insulation system has been identified in the literature as a significant aging stressor that can affect performance and lifetime of electric cables. Progressive reduction of the dielectric strength is commonly a result of water treeing which involves the development of permanent hydrophilic structures in the insulation coinciding with the absorption of water into the cable. Water treeing is a phenomenon in which dendritic microvoids are formed in electric cable insulation due to electrochemical reactions, electromechanical forces, and diffusion of contaminants over time. These reactions are caused by the combined effects of water presence and high electrical stresses in the material. Water tree growth follows a tree-like branching pattern, increasing in volume and length over time. Although these cables can be “dried out,” water tree degradation, specifically the growth of hydrophilic regions, is believed to be permanent and typically worsens over time. Based on established research, water treeing or water induced damage can occur in a variety of electric cables including XLPE, TR-XLPE and other insulating materials, such as EPR and butyl rubber. Once water trees or water induced damage form, the dielectric strength of an insulation material will decrease gradually with time as the water trees grow in length, which could eventually result in failure of the insulating material. Under wet conditions or in submerged environments, several environmental and operational parameters can influence water tree initiation and affect water tree growth. These parameters include voltage cycling, field frequency, temperature, ion concentration and chemistry, type of insulation material, and the characteristics of its defects. In this effort, a review of academic and industrial literature was performed to identify: 1) findings regarding the degradation mechanisms of submerged cabling and 2) condition monitoring methods that may prove useful in predicting the remaining lifetime of submerged medium voltage power cables. The research was conducted by a multi-disciplinary team, and sources included official NRC reports, national laboratory reports, IEEE standards, conference and journal proceedings, magazine articles, PhD dissertations, and discussions with experts. The purpose of this work was to establish the current state-of-the-art in material degradation modeling and cable condition monitoring techniques and to identify research gaps. Subsequently, future areas of focus are recommended to address these research gaps and thus strengthen the efficacy of the NRC’s developing cable condition monitoring program. Results of this literature review and details of the testing recommendations are presented in this report.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Indirect Tool Condition Monitoring Using Ensemble Machine Learning Techniques

Abstract Tool condition monitoring (TCM) has become a research area of interest due to its potential to significantly reduce manufacturing costs while increasing process visibility and efficiency. Machine learning (ML) is one analysis technique which has demonstrated advantages for TCM applications. However, the commonly studied individual ML models lack generalizability to new machining and environmental conditions, as well as robustness to the unbalanced datasets which are common in TCM. Ensemble ML models have demonstrated superior performance in other fields, but have only begun to be evaluated for TCM. As a result, it is not well understood how their TCM performance compares to that of individual models, or how homogeneous and heterogeneous ensemble models’ performances compare to one another. To fill in these research gaps, milling experiments were conducted using various cutting conditions, and the model groups were compared across several performance metrics. Statistical t-tests were also used to evaluate the significance of model performance differences. Through the analysis of four individual ML models and five ensemble models, all based on the processes’ sound, spindle power, and axial load signals, it was found that on average, the ensemble models performed better than the individual models, and that the homogeneous ensembles outperformed the heterogeneous ensembles.

Engineering↗
DOE OSTI2025

The CMS Phase-2 Fast Beam Condition Monitor prototype test with beam

The Fast Beam Condition Monitor (FBCM) is a standalone luminometer for the High Luminosity LHC (HL-LHC) program of the CMS Experiment at CERN. The detector is under development and features a new, radiation-hard, front-end application-specific integrated circuit (ASIC) designed for beam monitoring applications. The achieved timing resolution of a few nanoseconds enables the measurement of both the luminosity and the beam-induced background. The ASIC, called FBCM23, features six channels with adjustable shaping times, enabling in-field fine-tuning. Each ASIC channel outputs a single binary asynchronous signal encoding time-of-arrival and time-over-threshold information. The FBCM is based on silicon-pad sensors, with two sensor designs presently being considered. This paper presents the results of tests of the FBCM detector prototype using both types of silicon sensors with hadron, muon, and electron beams. Irradiated FBCM23 ASICs and silicon-pad sensors were also tested to simulate the expected conditions near the end of the detector's lifetime in the HL-LHC radiation environment. Based on test results, direct bonding between the sensor and ASIC was chosen, and an optimal bias voltage and ASIC threshold for FBCM operation were proposed. The current design of the front-end test board was validated following the beam test and is now being used for the first front-end module, which is expected to be produced in summer 2025. These results represent a major step forward in validating the FBCM concept, first version of the firmware and establishing a reliable design path for the final detector.

Beam-line instrumentation (beam position and profi↗
DOE OSTI2021

Novel Temperature Sensors and Wireless Telemetry for Active Condition Monitoring of Advanced Gas Turbines

The objective of the program is to develop and engine test hardware and software technologies that will enable active condition monitoring to be implemented on hot gas path turbine blades in large industrial gas turbines. The specific objectives are (1) to fabricate and install Smart Turbine Blades with thermally sprayed sensors and high temperature wireless telemetry systems in a gas turbine engine, (2) to integrate the component engine test data with remaining useful life (RUL) models and develop an approach for networking the component RUL data with Siemens' Power Diagnostics® engine monitoring system. These significant advances carried out in Phase 1 in temperature wide bandgap telemetry, along with new induced power driver and receiver geometry combined with an innovative approach to transmit digital data wirelessly will enable the opportunity to proceed with more technical innovation. The Phase 2 program focused on validation testing of sensor-wireless telemetry package in spin rig and advanced operation-based assessment (OBA) model utilizing artificial intelligence. Significant efforts were dedicated on the download of the technology onto components to be tested an actual gas turbine engine for full realization of active condition monitoring for Smart Turbine Blades.

03 NATURAL GAS↗
DOE OSTI2020

Development of an In-Situ Method for Cable Condition Monitoring in Nuclear Power Plants (SBIR Phase IIB Final Report)

This is the final report of a Small Business Innovation Research (SBIR) project that Analysis and Measurement Services Corporation (AMS) has conducted for the U.S. Department of Energy (DOE) over a seven-and-a-half year period (February 2013 through April 2020 with the awards of Phase I, Phase II and Phase IIB projects). The goal of the project was to design, develop, validate, and demonstrate a technique for in-situ testing of cable insulation polymers that will identify, locate, and provide the degree of aging for cables commonly used in nuclear power plants. During the Phase I project, AMS established that the frequency domain reflectometry (FDR) technique can successfully identify and measure cable insulation degradation that can be trended with aging. In Phase II, AMS performed extensive cable aging studies to correlate FDR measurements with other laboratory condition monitoring techniques and developed aging condition categories to quantify the severity of insulation degradation. In Phase IIB, the project expanded the research to include a wider variety of cable polymers that are used in the commercial nuclear power industry. This work also involved developing acceptance criteria to objectively assess age-related cable degradation while sharing the results of this research with industry, academia, and national laboratories to advance the state of the art in cable aging management technologies. The products developed under this research project provide the nuclear industry with an effective condition monitoring tool to support safe and long-term plant operation. Throughout the project, collaborations and support were received from a variety of industry organizations and individuals including DOE National Laboratories as well as nuclear plant utilities and several other industry experts and cable manufacturers. Contributions from these organizations included the donation of new cables, naturally aged cables, and research collaboration. The validation and commercialization of the products of this project were achieved through opportunities to test and demonstrate the technologies’ capabilities on-site at nuclear power generation and research facilities as well as in the laboratory alongside industry peers and cable testing service companies. The research resulted in a technology that can be used to identify, locate, and quantify age-related degradation in several types of cable polymers. This included developing software and hardware as well as the methodology for using the FDR technique to assess age-related degradation of installed cables. The technology developed under this project can provide nuclear plant management, engineers, and technicians with an in-situ electrical test method to determine if in-service cables need to be replaced, monitored on a periodic basis, or show no evidence of significant age-related degradation that may require action. Near the end of this Phase IIB project, the FDR product was sold to a nuclear power utility in South Korea. This sale of a dedicated aging assessment tool is the beginning of a comprehensive contract with the expectation of twelve (12) units sold to that country. Additionally, the FDR technology has been sold to several industry organizations including a nuclear research institute and the Diablo Canyon nuclear power plant. This technology is also being leased by other nuclear industry service companies for incorporation into aging management programs. The cable testing technology that was developed under this project was also integrated into a comprehensive cable aging assessment service that is being offered to the nuclear industry at the request of U.S. nuclear utilities and is currently part of onsite testing services provided by AMS.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS1973

Condition monitoring helps make the Space Shuttle Main Engine reusable

The Space Shuttle Main Engine (SSME) is a reusable, high-performance liquid-propellant rocket engine being developed for the Space Shuttle Orbiter Vehicle. The SSME has been designed for long life, rapid postflight maintenance, and a fast vehicle turnaround cycle of 160 hours. To meet the unique reusability requirements, the SSME considers maintainability and condition monitoring much as airlines do today. The condition monitoring capabilities designed into this engine are discussed with major emphasis on internal inspection and techniques which ensure the reusability of the SSME.

Lacroix, W. P.↗
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↗
DOE OSTI2019

Condition Monitoring of Wind Turbine Planetary Gearboxes Under Different Operating Conditions

Digitally enhanced services for wind power could reduce Operations and Maintenance costs as well as the Levelised Cost Of Energy. Therefore, there is a continuous need for advanced monitoring techniques which can exploit the opportunities of Internet of Things and Big Data Analytics. The heart of wind turbines is an epicyclic gearbox and rolling element bearings are often responsible for machinery stops. The vibration signatures of bearings are rather weak compared to other components. As a result a number of signal processing techniques have been proposed, focusing towards accurate and early fault detection with limited false alarms and missed detections. In Envelope Analysis an envelope of the vibration signal is estimated usually after filtering around a frequency band. Different tools, such as Kurtogram, have been proposed to select the optimum filter parameters. Monitoring techniques have reached a mature level for steady speed and load operating conditions. On the other hand, under chaniging operating conditions, it is still unclear whether the change of the monitoring indicators is due to the change of the machinery's health or due to the change of operating parameters. Recently, the authors have proposed a new tool called IESFOgram, based on Cyclic Spectral Coherence for the automatic selection of the filtering band. In this paper, the performance of the tool is evaluated on the National Renewable Energy Laboratory wind turbine gearbox vibration condition monitoring benchmarking data set which includes various faults with different levels of diagnostic complexity as well as various speed and load operating conditions.

17 WIND ENERGY↗