Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “maintenance optimization”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 469 records · Page 26

Advanced Solar and Load Forecasting Incorporating HD Sky Imaging (Phase III)

Due to rapidly changing sky conditions, the available solar irradiance for energy generation is subject to wide swings in amplitude. As the market penetration of solar energy continues to increase rapidly, these variations in solar power generation are beginning to have an impact on grid stability and increased wear on power switches. Solar power forecasting plays a critical role in operations for Independent System Operators (ISOs) and utilities. Accurate forecasts help maintain grid reliability, optimize generation from renewables, and reduce operating costs. Of particular interest to the ISOs and utilities are sudden changes in solar irradiance, termed “ramp events,” due to the movement of clouds. One significant impact of ramp events on the grid is additional ancillary service requirements necessary to manage such variability. Ramp events can also cause voltage fluctuations in the distribution grids and trigger actions of automated line equipment (e.g., tap changers), leading to additional maintenance costs. In high penetration solar regions, forecasts must be made for both transmission-connected and distribution-connected resources – either behind the meter or in front of it. Particularly for distributed solar energy resources, forecasting can be a challenge due to the lack of visibility of the energy resource. Brookhaven National Laboratory (BNL) has been working towards nowcasting Global Horizontal Irradiance (GHI) using low-cost technologies for several years now. The Solar NowCasting technology being developed by BNL is a 0 – 30 min solar “nowcasting” technology applicable to a scale covering both large generating facilities and residential, distributed solar installations that relies on a network of ground-based high-definition (HD) cameras and surface pyranometers. GHI forecasts are being produced for both regions using 8 ground-based HD cameras and at least 2 surface pyranometers. When stitched together, the camera images can be used to forecast the impact of clouds on available solar irradiance over a domain of ~50 km 2 . Phase I of the project was the engineering scale up conceptual design stage. Phase II was the initial field test and demonstration, in which the technology was scaled up by a factor of 20 times and successfully demonstrated in eastern Long Island. In Phase III, an additional forecasting network was added in upstate NY and both networks are currently being operated until at least a full year of data is gathered by the Albany network to allow for the collection of sufficient data to evaluate performance against the persistence and smart persistence models using the Solar Arbiter.

14 SOLAR ENERGY↗

Low-cost Retrofit Kit for Integral Reciprocating Compressors (IRCs) to Reduce Emissions and Enhance Efficiency

Methane emissions from natural gas engines within the oil and gas industry pose a significant environmental challenge, contributing approximately 34.1 MMTCO2 eq to the total of 239 MMTCO2 eq of methane emissions in 2021, according to the EPA report. In response to this pressing issue, a collaborative effort involving the University of Oklahoma and key industry partners—WAGO Automation, Mid Continental Rental, Elipsa, and Perscient—has resulted in the development of a retrofit kit designed to reduce emissions from integral reciprocating compressors (IRCs), which are integrated compressors and engines. The retrofit kit developed comprises an Air Management System (AMS), Integrated Sensors, and a Cloud-Connected Control Unit with Graphical User Interface (GUI)/Human-Machine Interface (HMI). This solution enhances operational efficiency, reduces emissions, and expands the operational envelope of IRCs in the natural gas industry. The project successfully completed all tasks, including the installation of a full-size IRC at a designated site in Oklahoma, the development of an optimized AMS, integration of sensors, and implementation of a data acquisition system. Significant achievements include a notable reduction in CH 4 emissions, up to 84% at specific loads, and the successful deployment of the retrofit kit in diverse field conditions. The system's capabilities were enhanced through the creation of a feedback control algorithm for the AMS using a correlation matrix illustrating relationships between engine parameters, and the design of a predictive and preventive maintenance platform. The project concluded with the deployment of the entire retrofit kit to another location, confirming its effectiveness in reducing emissions and enhancing IRC performance. The comprehensive solution offers valuable benefits for IRCs, making them invaluable assets in the natural gas industry.

03 NATURAL GAS↗

Nuclear Thermal Energy Storage Configurations for Industrial Combined Heat and Power Supply: Conceptual Study and Engineering Designs

The industries examined in this report primarily rely on moderate-temperature heat provided by gas- or coal-fired boilers and combined heat and power (CHP) plants, delivered through standard process steam systems. High-temperature energy demands are often industry-specific and typically exceed the capabilities of high-temperature gas-cooled reactors (HTGRs). While it is technically feasible to replace process steam from fossil-based heat sources with nuclear energy, certain industries, such as methanol production and pulp and paper, face technoeconomic challenges in integrating nuclear energy without major changes or a technological shift. This is mainly due to the limited external energy demand remaining after the use of internal byproducts, waste heat recovery, and simple efficiency improvements. Achieving full decarbonization of these processes with nuclear energy would require significant technological advancements, involving experimental technology and substantial investments, making widespread adoption in existing industrial plants unlikely in the near term. This study reviews TES options in the context of enabling a flexible CHP supply while maintaining a steady nuclear heat input. Heat storage systems that interface between the reactor primary fluid and the CHP system offer superior performance and flexibility. Specifically, steam extraction downstream of the reheater with a two-tank molten-salt TES appears as the best solution regarding thermodynamic system benefits and system drawbacks. Using selected system configurations, a conceptual design of an industrial energy park was developed for industries with varying energy demands, such as steel production plants utilizing electric arc furnaces (EAFs) and chemical plants, as well as for those with constant energy demands, like petroleum refineries. This design highlights the capabilities of TES and explores its potential business cases. The study also conceptually develops the potential for integrating additional energy sources with nuclear systems through the implementation of TES. The potential of the HTGR-TES-CHP system was also evaluated considering key uncertainties such as industrial demand profiles, external grid access availability, and eligible tax credit levels, using the Holistic Energy Resource Optimization Network. Sensitivity of net present value to these uncertainties was analyzed to determine the optimal number of nuclear reactors (and CHP systems) and the suitable TES capacity. The results were interpreted from a decision-maker’s perspective, focusing on three key areas: deployment strategy (oversized units vs. undersized units with TES support), industrial process characteristics (thermal-intensive single profiles vs. electricity-intensive combined profiles), and operational goals (maximizing profits vs. minimizing natural gas (NG) consumption or external grid dependence). The optimization results indicate that the HTGR-TES-CHP system significantly reduces reliance on NG boilers for individual industrial processes by 9-60% (in NG capacity factor), with an average reduction of 38%, compared to standalone NG boiler operation case (Business As Usual [BAU]). For combined industrial processes, the reduction ranges from 37-77%, with an average of 60%. Additionally, the system greatly reduces dependence on external grids. In meeting industrial electrical demands, a 33-100% self-sufficient internal electricity supply is achieved for single industrial process, with an average of 74%, compared to the BAU scenario, where 100% of electricity is imported. For combined processes, 35-100% of internal electricity demands are met by the reactor, with an average of 73%. At last, the relative NG price levels at which the proposed HTGR-TES-CHP system can cost-effectively enter the market currently dominated by existing NG boilers were estimated. For a moderate HTGR CAPEX level ($\$$2500/kWth, $\$$6329/kWe), the analysis suggests that NG prices must be 2.5 to 7 times higher than HTGR variable operating and maintenance costs for single industrial process, and 5.5 to 9.5 times higher for a combined process scenario. Tax credit modeling shows that the Investment Tax Credit significantly reduces the price threshold needed to break even, making the system competitive with NG boilers in certain cases.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Prime Time for Model-Predictive Control? Assessing the Technical and Market Readiness of Advanced Controls in Buildings

Despite three decades of extensive research and field testing that have consistently validated the benefits of Model Predictive Control (MPC) in building applications, the technology has seen limited market adoption. This paper evaluates the readiness of MPC for widespread deployment, showcases recent demonstrations and field tests across diverse building types, including residential, small commercial, large commercial, and campus settings. Our results demonstrate that MPC can optimize system operations to achieve load shifting, minimize curtailment of on-site generation, and reduce energy costs by up to 80 %, while maintaining or improving occupant comfort. We also show that MPC can effectively control large assets, such as MW-sized thermal storage systems, and respond to dynamic pricing signals. However, achieving scale remains difficult due to labor-intensive workflows, reliance on a “PhD-in-the-loop” for MPC design and maintenance, susceptibility to fragile data infrastructure, and persistent workforce education and acceptance barriers. To bridge this gap, we outline a transition from bespoke, labor intensive prototypes toward streamlined, segment-targeted deployment strategies that leverage model templates, semantic tools, and generative AI. By automating control configuration and reducing engineering effort, these recommendations provide a pathway for transforming successful research demonstrations into scalable, market ready solutions for MPC-based controls.

Pritoni, Marco↗

Community-Engaged Modeling of Urban Flood Adaptation Pathways

Climate change is intensifying the hydrologic cycle, leading to more frequent and severe rainfall-driven (pluvial) flooding in urban areas. In the mid-Atlantic US cities, aging and under-designed stormwater infrastructure is increasingly strained by these events, resulting in recurring damage to property and disruptions to transportation networks. In this study, we combine community engagement with hydrologic modeling to develop and evaluate potential urban flood adaptation strategies. Over a three-year period, local technical experts and community representatives met regularly to discuss flooding concerns, identify priorities, and co-develop adaptation strategies. These discussions informed the development of an urban flooding model (EPA Storm Water Management Model) for the Baltimore Harbor watershed, the focus location of this study. The flooding model integrates complex surface and subsurface stormwater infrastructure data, local expert knowledge, and community insights. We simulate stakeholder-prioritized adaptations, such as green and gray infrastructure strategies. Model results demonstrate that enhanced infrastructure maintenance is the most effective adaptation for reducing flood depths, but has varied effects across the watershed, and can increase flooding in some locations. Spatially concentrated greening provides limited benefit to the watershed as a whole, but moderate benefit in community priority areas. Together, these adaptations have the potential to reduce flood depths by as much as 58% in some locations, greatly reducing property damage and mobility impacts, primary concerns of stakeholders. Future work will implement robust optimization tools to search for adaptations which meet stakeholder objectives and perform highly under varied future climate conditions. This work contributes to the expanding literature on collaborative modeling and demonstrates that community-engaged approaches can enhance model credibility and generate more actionable insights for communities seeking to strengthen climate resilience.

Spangler, Ava [Pennsylvania State University] (ORC↗

Community-Informed Urban Flood Modeling for Impact Mitigation

Climate change is intensifying the hydrologic cycle, leading to more frequent and severe rainfall-driven (pluvial) flooding in urban areas. In the mid-Atlantic US cities, aging and under-designed stormwater infrastructure is increasingly strained by these events, resulting in recurring damage to property and disruptions to transportation networks. In this study, we combine community engagement with hydrologic modeling to develop and evaluate potential urban flood adaptation strategies. Over a three-year period, local technical experts and community representatives met regularly to discuss flooding concerns, identify priorities, and co-develop adaptation strategies. These discussions informed the development of an urban flooding model (EPA Storm Water Management Model) for the Baltimore Harbor watershed, the focus location of this study. The flooding model integrates complex surface and subsurface stormwater infrastructure data, local expert knowledge, and community insights. We simulate stakeholder-prioritized adaptations, such as green and gray infrastructure strategies. Model results demonstrate that enhanced infrastructure maintenance is the most effective adaptation for reducing flood depths, but has varied effects across the watershed, and can increase flooding in some locations. Spatially concentrated greening provides limited benefit to the watershed as a whole, but moderate benefit in community priority areas. Together, these adaptations have the potential to reduce flood depths by as much as 58% in some locations, greatly reducing property damage and mobility impacts, primary concerns of stakeholders. Future work will implement robust optimization tools to search for adaptations which meet stakeholder objectives and perform highly under varied future climate conditions. This work contributes to the expanding literature on collaborative modeling and demonstrates that community-engaged approaches can enhance model credibility and generate more actionable insights for communities seeking to strengthen climate resilience.

Baltimore MD↗

FASTER - A tool for DSN forecasting and scheduling

FASTER (Forecasting And Scheduling Tool for Earth-based Resources) is a suite of tools designed for forecasting and scheduling JPL's Deep Space Network (DSN). The DSN is a set of antennas and other associated resources that must be scheduled for satellite communications, astronomy, maintenance, and testing. FASTER consists of MS-Windows based programs that replace two existing programs (RALPH and PC4CAST). FASTER was designed to be more flexible, maintainable, and user friendly. FASTER makes heavy use of commercial software to allow for customization by users. FASTER implements scheduling as a two pass process: the first pass calculates a predictive profile of resource utilization; the second pass uses this information to calculate a cost function used in a dynamic programming optimization step. This information allows the scheduler to 'look ahead' at activities that are not as yet scheduled. FASTER has succeeded in allowing wider access to data and tools, reducing the amount of effort expended and increasing the quality of analysis.

Werntz, David↗

FASTER -- A Tool for DSN Forecasting and Scheduling

FASTER (Forecasting And Scheduling Tool for Earth-based Resources) is a suite of tools designed for forecasting and scheduling of JPL's DSN. The DSN is a set of antennas and other associated resources that must be scheduled for satellite communications, astronomy, maintenance, and testing. FASTER is a MS-Windows based program that replaces two existing programs (RALPH and PC4CAST). FASTER was designed to be more flexible, maintainable, and user friendly. FASTER makes heavy use of commercial software to allow for customization by users. FASTER implements scheduling as a two pass process: the first pass calculates a predictive profile of resource utilization; the second pass uses this information to calculate a cost function used in a dynamic programming optimization step. This information allows the scheduler to "look ahead" at activities that are not as yet scheduled. FASTER has succeeded in allowing wider access to data and tools, reducing the amount of effort expended and increasing the quality of analysis.

forecasting↗

Optimal operation of multi-plant steam district heating systems for enhanced efficiency and sustainability

Despite their crucial role in supplying heat and power to universities, industries, and healthcare facilities, many steam-based district heating systems rely on outdated control methods. Among these, multi-central plant districts are particularly challenging due to the complexities of coordinating multiple plants, optimizing load distributions, and managing system downtime. In response, new operational strategies are developed to enhance the efficiency and sustainability of steam districts while utilizing existing resources. These strategies include reducing plant operational pressure without compromising the reliable supply to buildings and optimizing load allocation across multiple plants. The load allocation considers boiler part-load efficiency, runtime, network losses, and building pressure set points, and is compared with traditional multi-boiler controls. To support this exploration, new dynamic Modelica models are developed. In addition, methods to reduce modeling complexities are incorporated, enhancing their suitability for practical applications. A holistic district-wide analysis using a real university case study demonstrates a 4.7% fuel savings by lowering boiler operational pressure from 900 kPa to 600 kPa, along with a 13.3% reduction in condensation losses across the distribution network. Furthermore, the load allocation approach results in a 13.1% reduction in fuel consumption during peak winter periods and 15.3% during shoulder periods, with corresponding decreases in carbon emissions and fuel costs. This approach can also save maintenance costs by reducing the boiler runtime by 49.6%. In conclusion, this research underscores the benefits of retrofitting aging steam district heating systems, offering immediate operational improvements by enhancing efficiency, meeting regulatory compliance, and extending infrastructure lifespans while delaying costly overhauls.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Optical design for the single crystal neutron diffractometer Pioneer

Pioneer is a single-crystal neutron diffractometer optimized for small-volume samples and weak signals at the Second Target Station at Oak Ridge National Laboratory. This paper presents the preliminary optical design progress, focusing on the rationale behind key design choices. It covers the T 0 and bandwidth disk choppers, guide and beam control system, incident-beam polarizer, scattering beam collimators, and additional strategies. The chopper locations are selected to maximize neutron transport while taking advantage of standardized shielding structures. To accommodate the maintenance shield, operational shutter, and polarizing V-cavity, the guide design includes significant gaps. When these optical components are moved out of the beam path, oversized collimators, rather than guides, will be translated in. Pioneer will utilize slit packages to control beam size and divergence and a translatable polarizing V-cavity. Absorbing panels are strategically placed near the end station to minimize background. An oscillating radial collimator, operating in a shift mode, will be used with the vertical cylindrical detector, while a fixed multi-cone collimator will be used with the bottom flat detector. In conclusion, these collimators will enable the detection of weak signals when complex sample environments are used.

47 OTHER INSTRUMENTATION↗

HPC Analytics of Fused Thermal Plants Data to Optimize Operating Envelope

In this project, ORNL extensively reviewed the ORAP RAM data, and it guided us to develop machine learning models that can predict time to next failures and forecast failure trends, which will be useful for optimizing power plant operation strategies. More specifically, we trained multiple random forest models and evaluated the model accuracy to validate with 10+ years of historical data. In addition, we implemented a web-based graphical user interface system for the models to show how our models can be used in more intuitive ways. This proof of concept allowed exploration of model use with power plant operators in mind. Developed machine learning models will be helpful for managing risks, planning maintenance and operation, ultimately reducing the down time and increasing the service hours. For future work, there are several interesting research topics including but not limited to model enhancement, creating synergy with traditional failure modeling approaches, and data-driven actionable recommendation and suggestions.

20 FOSSIL-FUELED POWER PLANTS↗

Lamb wave defect detection and evaluation using a fully non-contact laser system

Traditional Lamb wave structural health monitoring (SHM)/nondestructive evaluation (NDE) system employs contact type transducers such as PZT, ultrasonic transducers, and optical fibers. In application, transducer attachment and maintenance can be time and labor consuming. In addition, the use of couplant and adhesives can introduce additional materials on structures, and the interface coupling is often not well understood. To overcome these limitations, we proposed a fully non-contact NDE system by employing pulsed laser (PL) for Lamb wave actuation and scanning laser Doppler vibrometer (SLDV) for Lamb wave sensing. The proposed system is implemented on aluminum plates. The PL Lamb wave excitation is calibrated, and the optimal parameters are obtained. Lamb wave modes are then characterized through 1D wavefield analysis. With the calibrated and characterized system, defect detection and evaluation are achieved on aluminum plates with simulated defects (surfaced-bonded quartz rod, and machine milled crack) through 1D and 2D inspection in both time-space and frequency-wavenumber domains.

Ma, Zhaoyun↗

Testbed Demonstration of a Microgrid Building Block Prototype

With the adoption of ambitious climate action goals, the penetration level of distributed energy resources (DERs) is rapidly increasing. Microgrids are an efficient way to integrate these DERs, facilitating their operation and control. Additionally, microgrids enhance the overall resilience of the distribution system by serving critical loads both within and outside their boundaries. However, the need for substantial customized engineering leads to a high cost of development, installation and maintenance of microgrids. To address this challenge, Microgrid Building Blocks (MBB) are proposed to reduce the deployment cost of microgrids through modular, standardized design and implementation. This work presents a testbed demonstrating the integrated power conversion, control, and communication functionalities of an MBB. The testbed is formed by a real-time electromagnetic transient (EMT) simulation combined with a hardware and software prototype of MBB. The use cases supported by the MBB testbed are enumerated. The islanded operation, voltage regulation, and optimal dispatch capabilities of an MBB-based microgrid controller are validated through a case study.

Somda, Baza [Virginia Tech]↗

Robotics for the United States Space Station

Advances in robotics technology that will be necessary for the NASA Space Station to achieve its optimal level of automation are examined. The present state and emerging trends in teleoperator systems, hybrid teleoperated robots, and autonomous robots are reviewed, and scenarios of assembly, inspection, satellite servicing, and manufacturing are presented in order to illustrate potential uses of automation and robotics on the Space Station. Individual important technology development areas for Space Station robotics are surveyed, including end effectors and mechanization, control systems, telepresence and human factors, preception, manipulation in space, operation planning and data bases, and hardware maintenance.

Arnold, J. R.↗

[MaRS Project]

The Space Exploration Division of the Safety and Mission Assurances Directorate is responsible for reducing the risk to Human Space Flight Programs by providing system safety, reliability, and risk analysis. The Risk & Reliability Analysis branch plays a part in this by utilizing Probabilistic Risk Assessment (PRA) and Reliability and Maintainability (R&M) tools to identify possible types of failure and effective solutions. A continuous effort of this branch is MaRS, or Mass and Reliability System, a tool that was the focus of this internship. Future long duration space missions will have to find a balance between the mass and reliability of their spare parts. They will be unable take spares of everything and will have to determine what is most likely to require maintenance and spares. Currently there is no database that combines mass and reliability data of low level space-grade components. MaRS aims to be the first database to do this. The data in MaRS will be based on the hardware flown on the International Space Stations (ISS). The components on the ISS have a long history and are well documented, making them the perfect source. Currently, MaRS is a functioning excel workbook database; the backend is complete and only requires optimization. MaRS has been populated with all the assemblies and their components that are used on the ISS; the failures of these components are updated regularly. This project was a continuation on the efforts of previous intern groups. Once complete, R&M engineers working on future space flight missions will be able to quickly access failure and mass data on assemblies and components, allowing them to make important decisions and tradeoffs.

Aruljothi, Arunvenkatesh↗

An Overview of the Design and Optimized Operation of Vanadium Redox Flow Batteries for Durations in the Range of 4–24 Hours

An extensive review of modeling approaches used to simulate vanadium redox flow battery (VRFB) performance is conducted in this study. Material development is reviewed, and opportunities for additional development identified. Various crossover mechanisms for the vanadium species are reviewed, and their effects on its state of charge and its state of health assessed. A stack design focusing on flow fields and an electrode design tailored to various flow fields are reviewed. An operational strategy that takes these parameters into account is reviewed for various operating envelopes, chosen based on end user preference in terms of minimizing capital cost or operation and maintenance cost. This work provides a framework for the design and operation of a VRFB for various grid services.

25 ENERGY STORAGE↗

Characterization and optimization of hydrogen production by a salt water blue-green alga Oscillatoria sp. Miami BG 7. II - Use of immobilization for enhancement of hydrogen production

The technique of cellular immobilization was applied to the process of hydrogen photoproduction of nonheterocystous, filamentous marine blue-green alga, Oscillatoria sp. Miami BG 7. Immobilization with agar significantly improved the rate and longevity of hydrogen production, compared to free cell suspensions. Rates of H2 production in excess of 13 microliters H2 mg dry/wt h were observed and hydrogen production was sustained for three weeks. Immobilization also provided some stabilization to environmental variability and was adaptable to outdoor light conditions. In general, immobilization provides significant advantages for the production and maintenance of hydrogen photoproduction for this strain.

Phlips, E. J.↗