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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.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1985

Reusable rocket engine turbopump condition monitoring

Significant improvements in engine readiness with attendant reductions in maintenance costs and turnaround times can be achieved with an engine condition monitoring system (CMS). The CMS provides real time health status of critical engine components, without disassembly, through component monitoring with advanced sensor technologies. Three technologies were selected to monitor the rotor bearings and turbine blades: the isotope wear detector and fiber optic deflectometer (bearings), and the fiber optic pyrometer (blades). Signal processing algorithms were evaluated and ranked for their utility in providing useful component health data to unskilled maintenance personnel. Design modifications to current configuration Space Shuttle Main Engine (SSME) high pressure turbopumps and the MK48-F turbopump were developed to incorporate the sensors.

Hampson, M. E.↗
NASA NTRS1987

Reusable rocket engine optical condition monitoring

Plume emission spectrometry and optical leak detection are described as two new applications of optical techniques to reusable rocket engine condition monitoring. Plume spectrometry has been used with laboratory flames and reusable rocket engines to characterize both the nominal combustion spectra and anomalous spectra of contaminants burning in these plumes. Holographic interferometry has been used to identify leaks and quantify leak rates from reusable rocket engine joints and welds.

Wyett, L.↗
DOE OSTI2025

Predictive Modeling and Uncertainty Quantification in Condition Monitoring of Active Components: A Reactor Coolant Pump Use Case

This work develops data-driven models for onset of thermal barrier leakage in reactor coolant pumps. It incorporates uncertainty quantification to enhance the reliability and robustness of pre- dictions. Using synthetic data generated by the Generic Pressurized Water Reactor simulator, realistic degradation scenarios were simulated across lifecycle stages—beginning, middle, and end of life. Key variables, including differential pressure, flow rate, vibration, and temperatures, were analyzed using machine learning framework. The fully connected neural network models demonstrated exceptional performance, achieving R2 scores exceeding 0.99 and root mean square errors as low as around 8.23 × 10-2 gallon per minute (gpm) for the three stages of the lifecy- cle. UQ analysis further validated the model’s robustness, with narrow uncertainty bounds during steady-state operations and appropriately wider bounds during transitional phases, reflecting the physical behavior of the system. This work addresses important gaps in real-time condition moni- toring and regulatory compliance by integrating advanced condition monitoring technologies with UQ into IST programs. The ability to detect thermal barrier leakage early and quantify prediction reliability supports optimizing maintenance strategies while ensuring nuclear power plants’ safe and reliable operation.

99 - GENERAL AND MISCELLANEOUS↗
DOE OSTI2017

An Information Theoretic Framework and Self-organizing Agent- based Sensor Network Architecture for Power Plant Condition Monitoring

A central goal of the work was to enable both the extraction of all relevant information from sensor data, and the application of information gained from appropriate processing and fusion at the system level to operational control and decision-making at various levels of the control hierarchy through: 1. Exploiting the deep connection between information theory and the thermodynamic formalism, 2. Deployment using distributed intelligent agents with testing and validation in a hardware-in-the loop simulation environment. Enterprise architectures are the organizing logic for key business processes and IT infrastructure and, while the generality of current definitions provides sufficient flexibility, the current architecture frameworks do not inherently provide the appropriate structure. Of particular concern is that existing architecture frameworks often do not make a distinction between ``data'' and ``information.'' This work defines an enterprise architecture for health and condition monitoring of power plant equipment and further provides the appropriate foundation for addressing shortcomings in current architecture definition frameworks through the discovery of the information connectivity between the elements of a power generation plant. That is, to identify the correlative structure between available observations streams using informational measures. The principle focus here is on the implementation and testing of an emergent, agent-based, algorithm based on the foraging behavior of ants for eliciting this structure and on measures for characterizing differences between communication topologies. The elicitation algorithms are applied to data streams produced by a detailed numerical simulation of Alstom’s 1000 MW ultra-super-critical boiler and steam plant. The elicitation algorithm and topology characterization can be based on different informational metrics for detecting connectivity, e.g. mutual information and linear correlation.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS2000

Condition Monitoring for Helicopter Data

In this paper the classical "Westland" set of empirical accelerometer helicopter data is analyzed with the aim of condition monitoring for diagnostic purposes. The goal is to determine features for failure events from these data, via a proprietary signal processing toolbox, and to weigh these according to a variety of classification algorithms. As regards signal processing, it appears that the autoregressive (AR) coefficients from a simple linear model encapsulate a great deal of information in a relatively few measurements; it has also been found that augmentation of these by harmonic and other parameters can improve classification significantly. As regards classification, several techniques have been explored, among these restricted Coulomb energy (RCE) networks, learning vector quantization (LVQ), Gaussian mixture classifiers and decision trees. A problem with these approaches, and in common with many classification paradigms, is that augmentation of the feature dimension can degrade classification ability. Thus, we also introduce the Bayesian data reduction algorithm (BDRA), which imposes a Dirichlet prior on training data and is thus able to quantify probability of error in an exact manner, such that features may be discarded or coarsened appropriately.

Wen, Fang↗
NASA NTRS1987

Progress toward an advanced condition monitoring system for reusable rocket engines

A new generation of advanced sensor technologies will allow the direct measurement of critical/degradable rocket engine components' health and the detection of degraded conditions before component deterioration affects engine performance, leading to substantial improvements in reusable engines' operation and maintenance. When combined with a computer-based engine condition-monitoring system, these sensors can furnish a continuously updated data base for the prediction of engine availability and advanced warning of emergent maintenance requirements. Attention is given to the case of a practical turbopump and combustion device diagnostic/prognostic health-monitoring system.

Maram, J.↗
DOE OSTI2017

Dead-time optimization for SiC based voltage source converters using online condition monitoring

This paper introduces a dead-time optimization technique for a 2-level voltage source converter (VSC) using turn-off transition monitoring. Dead-time in a VSC impacts power quality, reliability, and efficiency. Silicon carbide (SiC) based VSCs are more sensitive to dead-time from increased reverse conduction losses and turn-off time variability with operating conditions and load characteristics. An online condition monitoring system for SiC devices has been developed using gate drive assist circuits and a micro-controller. It can be leveraged to monitor turn-off time and indicate the optimal dead-time in each switching cycle of any converter operation. It can also be used to specify load current polarity, which is needed for dead-time optimization in an inverter. This is an important distinction from other inverter dead-time elimination/optimization schemes as current around the zero current crossing is hard to accurately detect. A 1kW half-bridge inverter was assembled to test the turn-off time monitoring and dead-time optimization scheme. Results show 91% reduction in reverse conduction power losses in the SiC devices compared to a set dead-time of 500ns switching at 50 kHz.

Dyer, Jacob↗
DOE OSTI2026

Machine Learning–Based Condition Monitoring of a Circulating Water System of a Canadian Nuclear Plant

With the need to maintain long-term reliable energy using nuclear power plants, there is an underlying demand to ensure that the maintenance of plant components and systems is also done in an efficient and cost-effective manner. One way to achieve this is by moving from time-based maintenance to condition-based maintenance. The research presented in this paper focuses on applying statistical and machine-learning-based methods to capture anomalies within data for fault detection to further develop into condition monitoring. This paper focuses on system data for a circulating water system (CWS) of a pressurized heavy-water reactor for detecting anomalies. The different methodologies used for detecting and capturing anomalies in the CWS data are matrix profile, density-based spatial clustering of applications with noise (DBSCAN), and support vector machines (SVMs). Matrix profile and DBSCAN are used to distinguish between normal data and anomalous data. This paper presents a hybrid method using DBSCAN and SVM when a portion of the data is used for DBSCAN to generate clusters. This portion of data is then used to train the SVM along with the clusters generated by DBSCAN as output. SVM is then tested on unseen data as a predictive tool, which can work in real time to categorize data points as either normal or anomalous. This paper presents results that show the high accuracies of DBSCAN and SVM in capturing anomalies within the data for a CWS for fault detection. Thus, the maintenance plan would be focused on component condition rather than a time-based schedule by switching to an automated system to identify and predict faults within a CWS.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS1991

A ground test program to support condition monitoring of a spacecraft attitude control propulsion system

The Comet Rendezvous Asteroid Flyby (CRAF) mission involves seven years of flight from 0.6 to 4.57 Astronomical Units (AU), followed by about 915 days of maneuvering around a comet. Ground testing will characterize the very critical attitude control system thrusters' fuel consumption and performance for all anticipated fuel temperatures over thruster life. The ground test program characterization will support flight condition monitoring. A commercial software application hosted on a commercial microcomputer will control ground test operations and data acquisition using a newly designed thrust stand. The data acquisition and control system uses a graphics-based language and features a visual interface to integrate data acquisition and control.

Clark, Douglas J.↗
NASA NTRS2002

Condition Monitoring of Helicopter Gearboxes by Embedded Sensing

Health of helicopter gearboxes is commonly assessed by monitoring the housing vibration, thus it is challenged by poor signal-to-noise ratio of the signal measured away from the source. It is hypothesized that vibration measurements from sensors placed inside the gearbox will be much clearer indicators of faults and will eliminate many of the difficulties faced by present condition monitoring systems. This paper outlines our approach to devising such a monitoring system. Several tasks have been outlined toward this objective and the strategy to address each has been described. Among the tasks are wireless sensor design, antenna design, and selection of sensor locations.

Suryavanashi, Abhijit↗
DOE OSTI2020

WEC fault modelling and condition monitoring: A graph-theoretic approach

The nature of wave resources usually requires wave energy converter (WEC) components to handle peak loads (i.e., torques, forces, and powers) that are many times greater than their average loads, accelerating equipment degradation. Moreover, due to their isolated nature and harsh operating environment, WEC systems are projected to possess high operations and maintenance (O&M) cost, i.e., around 27% of their leveled cost of energy. As such, developing techniques to mitigate these costs through the application of condition monitoring and fault tolerant control will significantly impact the economic feasibility of grid connected WEC power. Toward this goal, models of faulty components are developed in the open source modeling platform, WEC-Sim, to estimate the performance and measurable states of a WEC operating with likely device and sensor failures. Two types of faulty component models are then applied to a point absorber WEC model with basic controller damping and spring forces. Resulting changes in device behavior are recorded as a benchmark, and a graph-theoretic approach is proposed for fault detection and identification utilizing multivariate time series. Simulation results demonstrate that these faults can greatly affect the WEC performance, and that the proposed method can effectively detect and classify different types of faults.

16 TIDAL AND WAVE POWER↗
DOE OSTI2018

Online condition monitoring based dead-time compensation for high frequency SiC voltage source inverter

Dead-time, device output capacitance, and other non-ideal characteristics cause voltage error for the midpoint PWM voltage of the semiconductor phase-leg employed in a voltage-source inverter (VSI). Voltage-second balancing is a well-known concept to mitigate this distortion and improve converter power quality. This paper proposes a unique voltage-second balancing scheme for a SiC based voltage source inverter using online condition monitoring of turn-off delay time and drain-source voltage rise/fall time. This data is sent to the micro-controller to be used in an algorithm to actively adjust the duty cycle of the input PWM gate signals to match the voltage-second of the non-ideal output voltage with an ideal output voltage-second. The monitoring system also allows for this implementation to eliminate the need for precise current sensing and allows for the implementation to be load independent. Dynamic current sensing is still a developing technology, and each load has a unique effect on the output voltage distortion. Test results for a 1 kW half-bridge inverter implementing this monitoring system and voltage-second balancing scheme show a 70% enhancement on the error against the ideal fundamental current value of the output current and a 2% THD improvement on the output current low frequency harmonics.

Dyer, Jacob↗
DOE OSTI2025

Federated Learning for Efficient Condition Monitoring and Anomaly Detection in Industrial Cyber-Physical Systems

Detecting and localizing anomalies in cyber-physical systems (CPS) has become increasingly challenging as systems grow in complexity, particularly due to varying sensor reliability and node failures in distributed environments. While federated learning (FL) offers a foundation for distributed model training, existing approaches lack mechanisms to handle these CPS-specific challenges. This paper presents an enhanced FL framework that introduces three key innovations: adaptive model aggregation based on sensor reliability, dynamic node selection for resource optimization, and Weibull-based checkpointing for fault tolerance. Our framework enables reliable condition monitoring while addressing the computational and reliability challenges of industrial CPS deployments. Experiments on NASA Bearing and Hydraulic System Datasets demonstrate superior performance over state-of-the-art FL methods, achieving 99.5% AUC-ROC in anomaly detection and maintaining accuracy under node failures. Statistical validation using Mann-Whitney (U) test confirms significant improvements (p < 0.05) in both detection accuracy and computational efficiency across diverse operational scenarios.1

Marfo, William [University of Texas at El Paso,Dep↗
NASA NTRS1989

OTVE turbopump condition monitoring, task E.5

Recent work has been carried out on development of isotope wear analysis and optical and eddy current technologies to provide bearing wear measurements and real time monitoring of shaft speed, shaft axial displacement and shaft orbit of the Orbit Transfer Vehicle hydrostatic bearing tester. Results show shaft axial displacement can be optically measured (at the same time as shaft orbital motion and speed) to within 0.3 mils by two fiberoptic deflectometers. Evaluation of eddy current probes showed that, in addition to measuring shaft orbital motion, they can be used to measure shaft speed without having to machine grooves on the shaft surface as is the usual practice for turbomachinery. The interim results of this condition monitoring effort are presented.

Coleman, Paul T.↗
DOE OSTI2015

Cable aging and condition monitoring of radiation resistant nano-dielectrics in advanced reactor applications

Cross-linked polyethylene (XLPE) nanocomposites have been developed in an effort to improve cable insulation lifetime to serve in both instrument cables and auxiliary power systems in advanced reactor applications as well as to provide an alternative for new or retro-fit cable insulation installations. Nano-dielectrics composed of different weight percentages of MgO & SiO 2 have been subjected to radiation at accumulated doses approaching 20 MRad and thermal aging temperatures exceeding 100 C. Depending on the composition, the performance of the nanodielectric insulation was influenced, both positively and negatively, when quantified with respect to its electrical and mechanical properties. For virgin unradiated or thermally aged samples, XLPE nanocomposites with 1wt.% SiO 2 showed improvement in breakdown strength and reduction in its dissipation factor when compared to pure undoped XLPE, while XLPE 3wt.% SiO 2 resulted in lower breakdown strength. When aged in air at 120 C, retention of electrical breakdown strength and dissipation factor was observed for XLPE 3wt.% MgO nanocomposites. Irrespective of the nanoparticle species, XLPE nanocomposites that were gamma irradiated up to the accumulated dose of 18 MRad showed a significant drop in breakdown strength especially for particle concentrations greater than 3 wt.%. Additional attenuated total reflectance Fourier transform infrared (ATR-FTIR) spectroscopy measurements suggest changes in the structure of the XLPE SiO 2 nanocomposites associated with the interaction of silicon and oxygen. Discussion on the relevance of property changes with respect to cable aging and condition monitoring is presented.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Test and Validate Distributed Coaxial Cable Sensors for in situ Condition Monitoring of Coal-Fired Boiler Tubes

This project aims to test, validate, and advance the technology readiness level (from TRL5 to TRL7) of a novel low-cost distributed stainless-steel/ceramic coaxial cable sensing (SSC-CCS) technology for in situ monitoring of the boiler tube temperature in existing coal-fired power plants. The novel SSC-CCS sensing technology and associated condition-based monitoring (CBM) software to be demonstrated in this project will lead to an improved understanding of the boiler tube failure mechanisms and a prognostic system to improve the overall performance, reliability, and flexibility of the nation’s coal-fired power plant fleet. A boiler tube monitoring system with distributed coaxial cable temperature sensors and a sensor acquisition system was constructed. The high-temperature coaxial cable sensor with a length of 1.3m was made by using a quartz tube (1mm inner diameter (ID) and 6mm outer diameter (OD)) to concentrically separate a 304 stainless-steel (SS) rod (1mm OD) and SS tube (7.94mm OD and 6.16mm ID). The sensor acquisition system includes a vector network analyzer (VNA), a radio frequency (RF) power amplifier, multiple switches and a USB hub. The distributed stainless-steel quartz coaxial cable sensor (SSQ-CCS) had a linear response to temperature with a resolution uncertainty of σ = 0.77℃. To withstand the harsh conditions of 3,300 steam pressures and 800℃ high temperatures, the sensor was shielded by a protective tube made of the same material as the boiler tube. The protection tube had an OD of 1.5 inches and a thickness of 0.25 inches. In the laboratory tests, the sensor showed good sensitivity and fast response. The drift was bounded between +0.33% and -0.67% during a test at 600℃ for 350 hours, indicating good stability of the sensor. A field test was conducted where four sensors were welded on four superheat tubes (SH-Ts) at a coal-fired power station over 400 days. Conventional thermocouples were welded to the superheater tubes alongside the coaxial cable sensors for the purpose of comparison. Two sensors were capable of distributed sensing, with three multiplexed sensing sections. The other two sensors were single section. During the 400-day test period, the power plant experienced startups and shutdowns. At the steady state operations, the temperature of the boiler tube is about 600℃ (1112°F). The sensors recorded the entire coal-firing processes (start-up, steady state, and shut-down) and the glitch event. A GSM modem and a Watchdog were added to the system to ensure reliable data recording. The GSM modem sent daily messages to plant managers and Clemson team to inform the status of the sensor system. If the system was not normally working, the Watchdog would reboot the system automatically. The new coaxial cable based distributed sensing technology has been proven to be successful in both laboratory and field tests. A comprehensive four-stage multi-physics computational framework has been developed to assist the design, optimization, installation, and operation of SSQ-CCS. With the consideration of various operation conditions, we predict the distributions of flue gas temperatures within coal-fired boilers, the temperature correlation between the boiler tube and SSQ-CCS, and the safety of SSQ-CCS. A conditional-based monitoring system is implemented as well. The computational framework developed in this work can guide the future operation of coal-fired plants and other power plants for the safety prediction of boiler operations.

01 COAL, LIGNITE, AND PEAT↗