Results for “PROCESS CONTROL” — Page 33

NASA NTRS1995

Designing for Small Volume Assembly of Advanced Electronics Packages

We describe a general methodology to Design for Producibility and Reliability (DFPAR) for very small volume production runs. In cases where the entire volume for fabrication is less than five products, traditional Statistical Process Control (SPC) is inadequate due to reliance on statistics of much larger volumes and the Central Limit Theorem. Data acquisition for process parameter estimation from such a small sample size is difficult; however, it is critical to producing high reliability product.

Central Limit Theorem statistics high reliability ↗

NASA NTRS1993

Welding process modelling and control

The research and analysis performed, and software developed, and hardware/software recommendations made during 1992 in development of the PC-based data acquisition system for support of Welding Process Modeling and Control is reported. A need was identified by the Metals Processing Branch of NASA Marshall Space Flight Center, for a mobile data aquisition and analysis system, customized for welding measurement and calibration. Several hardware configurations were evaluated and a PC-based system was chosen. The Welding Measurement System (WMS) is a dedicated instrument, strictly for the use of data aquisition and analysis. Although the WMS supports many of the functions associated with the process control, it is not the intention for this system to be used for welding process control.

Romine, Peter L.↗

DOE OSTI2018

Steam Reforming Process for Treating Radioactive Waste - 18172

In 2005 the THOR steam reforming fluidized-bed reactor (FBR) technology was selected by the DOE for treatment of sodium-bearing waste (SBW) at the INL. During commissioning a number of equipment reliability and process control challenges were encountered preventing the start of radiological operations. To address these challenges the team adopted a phased systematic mechanistic approach, underpinned by scientific principles and supported by some of the world's leading experts in FBR technology. The Phase 1 effort broadly addressed the entire plant and associated modifications. Phase 2 focused on the most critical issues associated with the denitration and mineralization reformer (DMR) vessel: specifically, mitigation of wall scale (mineral deposits) that formed on the inside of the DMR; mitigation of friable agglomerates (sand-castles) that caused operational instabilities; repair of damaged lower fluidizing gas distributor (ring header), and resolution of auger-grinder (A/G) reliability issues. Basic chemistry and fluidization, as well as operational issues were evaluated using engineering analysis, modeling, bench-scale, pilot scale, and full-scale runs to validate the resolutions. The bench scale testing revealed the need to ensure at least a 5 vol% concentration of CO{sub 2} in the fluidizing gas to minimize undesirable reaction intermediates that could form in less fluidized regions of the bed. Engineering analysis and modeling results pointed to the need to redesign the fluidizing gas distributor to overcome fluidization problems. Chemistry evaluations guided efforts to minimize the deposition of wall-scale. The process modifications were confirmed on the pilot level and are being validated in the full-scale unit (Phase 3). (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2014

Concept, implementation and commissioning of the automation system for the accelerator module test facility AMTF

The European XFEL project launched on June 5, 2007 will require about 103 accelerator modules as a main part of the XFEL linear accelerator. All superconducting components constituting the accelerator module like cavities and magnets have to be tested before the assembly. For the tests of the individual cavities and the complete modules an XFEL Accelerator Module Test Facility (AMTF) has been erected at DESY. The process control system EPICS (Experimental Physics and Industrial Control System) is used to control and operate the cryogenic plant and all its subcomponents. A complementary component of EPICS is the Open Source software suit CSS (Control System Studio). CSS is an integrated engineering, maintenance and operating tool for EPICS. CSS enables local and remote operating and monitoring of the complete system and thus represents the human machine interface. More than 250 PROFIBUS nodes work at the accelerator module test facility. DESY installed an extensive diagnostic and condition monitoring system. With these diagnostic tools it is possible to examine the correct installation and configuration of all PROFIBUS nodes in real time. The condition monitoring system based on FDT/DTM technology shows the state of the PROFIBUS devices at a glance. This information can be used for preventive maintenance which is mandatory for continuous operation of the AMTF facility. The poster will describe all steps form engineering to implementation and commissioning.

43 PARTICLE ACCELERATORS↗

DOE OSTI2015

Modeling precursor diffusion and reaction of atomic layer deposition in porous structures

Atomic layer deposition (ALD) is a technique for depositing thin films of materials with a precise thickness control and uniformity using the self-limitation of the underlying reactions. Usually, it is difficult to predict the result of the ALD process for given external parameters, e.g., the precursor exposure time or the size of the precursor molecules. Therefore, a deeper insight into ALD by modeling the process is needed to improve process control and to achieve more economical coatings. In this paper, a detailed, microscopic approach based on the model developed by Yanguas-Gil and Elam is presented and additionally compared with the experiment. Precursor diffusion and second-order reaction kinetics are combined to identify the influence of the porous substrate's microstructural parameters and the influence of precursor properties on the coating. The thickness of the deposited film is calculated for different depths inside the porous structure in relation to the precursor exposure time, the precursor vapor pressure, and other parameters. Good agreement with experimental results was obtained for ALD zirconiumdioxide (ZrO{sub 2}) films using the precursors tetrakis(ethylmethylamido)zirconium and O{sub 2}. The derivation can be adjusted to describe other features of ALD processes, e.g., precursor and reactive site losses, different growth modes, pore size reduction, and surface diffusion.

36 MATERIALS SCIENCE↗

DOE OSTI2013

Development of ITM Oxygen Technology for Integration in IGCC and Other Advanced Power Generation DECISION POINT 1 UNDER PHASE 3

Air Products and the DOE have partnered over a number of years in the development of ITM Oxygen technology in support of gasification technology. Throughout this process, studies of application of the technology to IGCC and oxy-coal combustion have shown significant reduction in capital and operating costs compared to similar systems using conventional cryogenic air separation. Phase 3, the current phase of the program, focuses on the design, construction and operation of a 30- to 100-TPD pilot facility, the Intermediate Scale Test Unit (ISTU). Execution of this phase to date has resulted in significant advances in a number of areas including ceramic membrane material development, module design and production, ceramic-to-metal seal design, process control strategies, and engineering development of process cycles. Phase 3 will be complete upon successful operation of the ISTU in a series of tests making oxygen from ceramic membrane modules and producing power from a hot gas expander. Phase 3 work has extended beyond the planned schedule due to a delay in delivery of equipment from vendors. Air Products is currently managing the equipment delay by close involvement with the vendor to redesign the problematic equipment and oversee its fabrication. The result of these unforeseen challenges is that the ISTU project completion date has been delayed. Tight cost controls have been implemented both by DOE program management and APCI to meet budget constraints despite increased costs due to budget delays. Total project costs have increased in several areas. Increased costs in the ISTU project include purchased equipment, instruments, construction, and contractor engineering. Increased costs for other tasks include additional work in support of module production by Ceramatec, Inc, and increased Air Products labor for component testing. Air Products plans to complete testing as outlined in the SOPO and successfully complete all project objectives by the end of FY14.

Anderson, Lori↗

NASA NTRS1962

ON THE UNIQUENESS OF TIME-OPTIMAL CONTROL FOR LINEAR PROCESSES

Uniqueness of time-optimal control for linear processes

LINEAR SYSTEM↗

NASA NTRS1992

Intelligent Processing Equipment Projects at DLA

The Defense Logistics Agency is successfully incorporating Intelligent Processing Equipment (IPE) into each of its Manufacturing Technology thrust areas. Several IPE applications are addressed in the manufacturing of two 'soldier support' items: combat rations and military apparel. In combat rations, in-line sensors for food processing are being developed or modified from other industries. In addition, many process controls are being automated to achieve better quality and to gain higher use (soldier) acceptance. IPE applications in military apparel include: in-process quality controls for identification of sewing defects, use of robots in the manufacture of shirt collars, and automated handling of garments for pressing.

Obrien, Donald F.↗

DOE OSTI2018

Renovation of Thermal Vacuum Chambers at Idaho National Laboratory (INL) for Testing of Radioisotope Power Systems (RPS)

The Radioisotope Power Systems (RPS) program at Idaho National Laboratory (INL) fuels and performs environmental testing of RPS in support of National Aeronautics and Space Administration (NASA) missions. Recently the programs’ thermal vacuum chambers, housed within INL’s Space and Security Power Systems Facility (SSPSF), underwent successful renovations to improve functional capabilities and system control in support of customer missions. Thermal vacuum system renovations focused primarily on three core functions. The first focus area was integration of semi-automated Programmable Logic Controllers (PLC) to enhance operational feedback and process control. This included the use of numerically controlled vacuum valves and integration of real time feedback from process pressure transducers. Improvements to the system high vacuum pumping technology was the second priority focus. Legacy diffusion pumps were replaced with turbo-molecular and cryogenic pumps to help mitigate the possibility of back streaming diffusion pump oil onto the surface of the test article or radiative cooling surfaces located within the chambers. The third and final core function involved meeting emergent customer thermal requirements. This led to retro-fitting one of the vacuum chambers with a cryogenically cooled Thermal Conditioning Unit (TCU) and thermal shrouds. The TCU utilizes gaseous nitrogen to heat or cool a cylindrical shroud to maintain a set temperature with a programmable range of -I85 °C to I00 °C. With the successful completion of RPS acceptance testing, the newly renovated thermal vacuum chamber systems are operational and better equipped to support testing of Radioisotope Power Systems for space exploration missions.

42 ENGINEERING↗

DOE OSTI2018

Renovation of Thermal Vacuum Chambers at Idaho National Laboratory for Testing of Radioisotope Power Systems

The Radioisotope Power Systems (RPS) program at Idaho National Laboratory (INL) fuels and performs environmental testing of RPS in support of National Aeronautics and Space Administration (NASA) missions. Recently the programs’ thermal vacuum chambers, housed within INL’s Space and Security Power Systems Facility (SSPSF), underwent successful renovations to improve functional capabilities and system control in support of customer missions. Thermal vacuum system renovations focused primarily on three core functions. The first focus area was integration of semi-automated Programmable Logic Controllers (PLC) to enhance operational feedback and process control. This included the use of numerically controlled vacuum valves and integration of real time feedback from process pressure transducers. Improvements to the system high vacuum pumping technology was the second priority focus. Legacy diffusion pumps were replaced with turbo-molecular and cryogenic pumps to help mitigate the possibility of back streaming diffusion pump oil onto the surface of the test article or radiative cooling surfaces located within the chambers. The third and final core function involved meeting emergent customer thermal requirements. This led to retro-fitting one of the vacuum chambers with a cryogenically cooled Thermal Conditioning Unit (TCU) and thermal shrouds. The TCU utilizes gaseous nitrogen to heat or cool a cylindrical shroud to maintain a set temperature with a programmable range of -I85 °C to I00 °C. With the successful completion of RPS acceptance testing, the newly renovated thermal vacuum chamber systems are operational and better equipped to support testing of Radioisotope Power Systems for space exploration missions.

42 ENGINEERING↗

DOE OSTI2018

Renovation of Thermal Vacuum Chambers at Idaho National Laboratory (INL) for Testing of Radioisotope Power Systems (RPS)

The Radioisotope Power Systems (RPS) program at Idaho National Laboratory (INL) fuels and performs environmental testing of RPS in support of National Aeronautics and Space Administration (NASA) missions. Recently the programs’ thermal vacuum chambers, housed within INL’s Space and Security Power Systems Facility (SSPSF), underwent successful renovations to improve functional capabilities and system control in support of customer missions. Thermal vacuum system renovations focused primarily on three core functions. The first focus area was integration of semi-automated Programmable Logic Controllers (PLC) to enhance operational feedback and process control. This included the use of numerically controlled vacuum valves and integration of real time feedback from process pressure transducers. Improvements to the system high vacuum pumping technology was the second priority focus. Legacy diffusion pumps were replaced with turbo-molecular and cryogenic pumps to help mitigate the possibility of back streaming diffusion pump oil onto the surface of the test article or radiative cooling surfaces located within the chambers. The third and final core function involved meeting emergent customer thermal requirements. This led to retro-fitting one of the vacuum chambers with a cryogenically cooled Thermal Conditioning Unit (TCU) and thermal shrouds. The TCU utilizes gaseous nitrogen to heat or cool a cylindrical shroud to maintain a set temperature with a programmable range of -I85 °C to I00 °C. With the successful completion of RPS acceptance testing, the newly renovated thermal vacuum chamber systems are operational and better equipped to support testing of Radioisotope Power Systems for space exploration missions.

42 ENGINEERING↗

DOE OSTI2012

Solid State Lighting Program (Falcon)

Over the past two years, KLA-Tencor and partners successfully developed and deployed software and hardware tools that increase product yield for High Brightness LED (HBLED) manufacturing and reduce product development and factory ramp times. This report summarizes our development effort and details of how the results of the Solid State Light Program (Falcon) have started to help HBLED manufacturers optimize process control by enabling them to flag and correct identified killer defect conditions at any point of origin in the process manufacturing flow. This constitutes a quantum leap in yield management over current practice. Current practice consists of die dispositioning which is just rejection of bad die at end of process based upon probe tests, loosely assisted by optical in-line monitoring for gross process deficiencies. For the first time, and as a result of our Solid State Lighting Program, our LED manufacturing partners have obtained the software and hardware tools that optimize individual process steps to control killer defects at the point in the processes where they originate. Products developed during our two year program enable optimized inspection strategies for many product lines to minimize cost and maximize yield. The Solid State Lighting Program was structured in three phases: i) the development of advanced imaging modes that achieve clear separation between LED defect types, improves signal to noise and scan rates, and minimizes nuisance defects for both front end and back end inspection tools, ii) the creation of defect source analysis (DSA) software that connect the defect maps from back-end and front-end HBLED manufacturing tools to permit the automatic overlay and traceability of defects between tools and process steps, suppress nuisance defects, and identify the origin of killer defects with process step and conditions, and iii) working with partners (Philips Lumileds) on product wafers, obtain a detailed statistical correlation of automated defect and DSA map overlay to failed die identified using end product probe test results. Results from our two year effort have led to “automated end-to-end defect detection” with full defect traceability and the ability to unambiguously correlate device killer defects to optically detected features and their point of origin within the process. Success of the program can be measured by yield improvements at our partner’s facilities and new product orders.

Meeks, Steven↗

DOE OSTI2022

MPC4CLR (Model-Predictive-Control-for-Critical-Load-Restoration-in-Power-Distribution-Systems) [SWR-22-24]

Model predictive control (MPC) is a system or process control technique for making decisions under uncertainty via rolling look-ahead optimizations at each control step where only the current step decisions are applied, and the rest are discarded. In this work, we developed an MPC for a critical load restoration (CLR) in power distribution systems to recover system service (electricity delivery) following an extreme event-triggered substation outage. The method considers the problem of controlling distributed energy resources (DERs) of the distribution system with the objective of achieving maximum load pick up while satisfying distribution network flow and voltage constraints. A linearized optimal power flow (OPF) model is employed to represent the physics of the network. The problem formulation is augmented with a ramping (up) reserve product for the DERs to ensure improved and upward monotonic load restoration as time evolves. Simulation analysis and performance tests are performed using a modified IEEE 13-bus test feeder integrated with wind, solar, microturbine, and energy storage battery. The software is developed using various software packages in Julia and Python. The MPC model is implemented using the JuMP optimization language in Julia while the data analytics including renewable generation and load demand forecasts, running the MPC simulation and visualizations is performed in Python.

Eseye, Abinet Tesfaye↗

DOE OSTI2025

Dynamic Model of a supercritical CO2 10MW Recompression Closed Brayton Cycle

This model of the 10MW recompression closed Brayton cycle (RCBC) was developed in conjunction with the DOE’s Supercritical Transformational Electric Power (STEP) project. A high-fidelity dynamic model was used extensively to study the dynamic characteristics of the cycle and develop the process control architecture and strategies for start-up and shutdown procedures. This version of the model has been simplified from the original version to be more accessible for a variety of applications and research. The controllers developed for the original model have been maintained for this version and tuned to give a similar performance to the original model. This model can be used to perform similar studies as those performed in Liese et al (2020). The overall cycle performance will not be identical but will perform similarly.

Controls,Power Cycles,Process Systems Engineering,↗

DOE OSTI2014

Nuclear Security: Quantifying Late Detection in MC&A

The objectives of this presentation are to understand the concept of late detection; review the statistics used in MC&A; specify the Pd and timelines for Pd for MC&A elements for item inventories; review elements of process control as they relate to bulk processes; and specify the timelines and detection thresholds for Pd for MC&A elements for bulk or Processing Operations.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

DOE OSTI2019

Chemical Kinetic Effects on Detonation Wave Generation in a Semi-Bounded Channel

The coupled effects of mixing and ignition are investigated in a semi-bounded channel that emulates a rotating detonation engine geometry. In previous studies, a robust mechanism of self-excited detonation wave generation was discovered with O 2 /CH 4 reactants in this experiment. The behavior requires symbiosis between the chemical kinetics of the reactant mixture and the dynamics of the reactant injection process. The reactant jet dynamics are controlled principally by the geometry of the system and the pressure differences across the injector. The chemical kinetics are modified by changing the reactant composition to investigate how the combustion behavior changes when the kinetics become the rate-controlling process. Ignition delay timescales are increased by introducing an inert gas, N 2 , to the oxidizer flow; conversely, ignition delay time-scales are decreased by replacing natural gas fuel with hydrogen, H 2 . The effects of the oxidizer modifications to the chemical kinetics for each fuel are studied independently to characterize the amplification process associated with the self-excited instability, and apply this understanding to the sustainability of detonations in a comparable RDE environment.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2015

Magnetotactic Bacteria as Potential Sources of Bioproducts

Magnetotactic bacteria (MTB) produce intracellular organelles called magnetosomes which are magnetic nanoparticles composed of magnetite (Fe3O4) or greigite (Fe3S4) enveloped by a lipid bilayer. The synthesis of a magnetosome is through a genetically controlled process in which the bacterium has control over the composition, direction of crystal growth, and the size and shape of the mineral crystal. As a result of this control, magnetosomes have narrow and uniform size ranges, relatively specific magnetic and crystalline properties, and an enveloping biological membrane. These features are not observed in magnetic particles produced abiotically and thus magnetosomes are of great interest in biotechnology. Most currently described MTB have been isolated from saline or brackish environments and the availability of their genomes has contributed to a better understanding and culturing of these fastidious microorganisms. Moreover, genome sequences have allowed researchers to study genes related to magnetosome production for the synthesis of magnetic particles for use in future commercial and medical applications. Here, we review the current information on the biology of MTB and apply, for the first time, a genome mining strategy on these microorganisms to search for secondary metabolite synthesis genes. More specifically, we discovered that the genome of the cultured MTB Magnetovibrio blakemorei, among other MTB, contains several metabolic pathways for the synthesis of secondary metabolites and other compounds, thereby raising the possibility of the co-production of new bioactive molecules along with magnetosomes by this species.

magnetosomes↗

DOE OSTI2026

A Compact Cryogenic Environment for In Situ Neutron Diffraction Under Mechanical Loading

Understanding the deformation mechanisms of materials at cryogenic temperatures is crucial for cryogenic engineering applications. In situ neutron diffraction is a powerful technique for probing such mechanisms under cryogenic conditions. In this study, we present the development of a compact cryogenic environment (CCE) designed to facil-itate in situ neutron diffraction experiments under mechanical loading at tempera-tures as low as 77 K. The CCE features a polystyrene foam cryogenic chamber, alumi-num blocks serving as neutron-transparent cold sinks, a liquid nitrogen dosing system for cryogen delivery, a nitrogen gas flow control system for thermal management, a process controller for temperature control, and a pair of thermally isolated grip adapt-ers for mechanical testing. The CCE achieves reliable temperature control with mini-mal neutron attenuation. Utilizing this setup, we conducted three in situ neutron dif-fraction tensile tests on a 316L stainless steel at 77 , 173 , and 298 K, respectively. The results highlight the pronounced effects of cryogenic temperatures on the material's deformation mechanisms, underscoring both the significance of cryogenic deformation studies and the effectiveness of the CCE.

Yu, Dunji [ORNL] (ORCID:0000000189467851)↗