48-0001 - Transition to Maintenance Excellence (MxE) Implementation and Data-Driven Optimization
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Deckard, Tobias Wayne [Los Alamos National Laborat↗
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Results for “maintenance optimization”
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Adaptive Framework for Maintenance Scheduling Based on Dynamic Preventive Intervals and Remaining Useful Life Estimation
Data-based prognostic methods exploit sensor data to forecast the remaining useful life (RUL) of industrial settings to optimize the scheduling of maintenance actions. However, implementing sensors may not be cost-effective or practical for all components. Traditional preventive approaches are not based on sensor data; however, they schedule maintenance at equally spaced intervals, which is not a cost-effective approach since the distribution of the time between failures changes with the degradation state of other parts or changes in working conditions. This study introduces a novel framework comprising two maintenance scheduling strategies. In the absence of sensor data, we propose a novel dynamic preventive policy that adjusts intervention intervals based on the most recent failure data. When sensor data are available, a method for RUL prediction, designated k-LSTM-GFT, is enhanced to dynamically account for RUL prediction uncertainty. The results demonstrate that dynamic preventive maintenance can yield cost reductions of up to 51.8% compared to conventional approaches. The predictive approach optimizes the exploitation of RUL, achieving costs that are only 3–5% higher than the minimum cost achievable while ensuring the safety of critical systems since all of the failures are avoided.
Nunes, Pedro (ORCID:0000000180012172)↗
An Axenic Plant Culture System for Optimal Growth in Long-Term Studies: Design and Maintenance
The symbiotic co-evolution of plants and microbes leads to difficulties in understanding which of the two components is responsible for a given environmental response. Plant-microbe studies greatly benefit from the ability to grow plants in axenic (sterile) culture. Several studies have used axenic plant culture systems, but experimental procedures are often poorly documented, the plant growth environment is not optimal, and axenic conditions are not rigorously verified. We developed a unique axenic system using inert components that promotes plant health and can be kept sterile for at least 70 d. Crested wheatgrass (Agropyron cristatum cv. DII) plants were grown in sand within flow-through glass columns that were positively pressured with filtered air. Plant health was optimized by regulating temperature, light level, CO2 concentration, humidity, and nutrients. The design incorporates several novel aspects, such as pretreatment of the sand with Fe, graduated sand layers to optimize the air-water balance of the root zone, and modification of a laminar flow hood to serve as a plant growth chamber. Adaptations of several sterile techniques were necessary for maintenance of axenic conditions. Axenic conditions were verified by plating and staining leachates as well as rhizoplane stain. This system was designed to study nutrient and water stress effects on root exudates, but is useful for assessing a broad range of plant-microbe-environment interactions. Based on total organic C analysis, 74% of exudates was recovered in the leachate, 6% was recovered in the bulk sand, and 17% was recovered in the rhizosphere sand. Carbon in the leachate after 70 d reached 255 micro-g/d. Fumaric, malic, malonic, oxalic, and succinic acids were measured as components of the root exudates.
Henry, Amelia↗
Fault Characterization and Diagnostics Supporting Condition-Based Operation and Maintenance of Gas Turbine Engines
Condition-Based Operation and Maintenance (CBOM) is the state-of-the-art in maintenance approaches for gas turbine engines. CBOM applies engine sensor information to the optimization of future operation and maintenance procedures; this technique reduces costs for engine operators by minimizing unplanned outages and catastrophic engine degradation. However, due to the complexities of gas turbine operation and the lack of available engine sensors, further development is required to fully realize the benefits of CBOM. In the turbine section, rotating components interact with high temperature flows, which creates intense thermal and mechanical stresses. As a result, there are numerous mechanisms of component degradation in the turbine section. Furthermore, turbine components – like stator vanes and rotor blades – are among the most expensive in the engine because they are complex to design and manufacture. For these reasons, this dissertation addresses two main questions: (i) which parameters or faults within the turbine section are most important to monitor, and (ii) how can these parameters or faults be monitored in an engine-relevant environment? Although many turbine parameters and faults have been investigated in the open literature, there are some faults that are still not well understood. Rotor-casing eccentricity, which causes a non-constant blade tip clearance around the annulus, has not been investigated in terms of its effects on turbine efficiency. Therefore, the first study in this dissertation quantifies overall and local turbine efficiency for varying levels of rotor-casing eccentricity. Results showed negligible variations to overall turbine efficiency, meaning rotor-casing eccentricity only becomes relevant to CBOM when its severity causes rotordynamic issues. Purge flow is critical to turbine hardware longevity because it prevents ingestion of hot main gas path (MGP) flow into the under-platform regions. Despite its importance, there are currently no methods for monitoring purge flow performance in an engine environment. Therefore, the second study in this dissertation develops a predictive model for sealing effectiveness using inputs from two fast-response pressure sensors. Results exhibited low prediction errors across a full range of purge flow rates, which supports the viability of the modelling approach for CBOM. The final two studies in this dissertation address blade coolant flow monitoring. This cooling flow is responsible for protecting the turbine blades from the MGP flow, which exits the combustor at temperatures greater than the blade melting point. These studies showed that temperature measurements on the blade surface can be used to accurately predict blade coolant flow rate, and that defining the candidate features relative to the coolant trajectory is important for maintaining accuracy as coolant flow rate degradation occurs. This work enables blade coolant flow monitoring, which is currently not possible through existing condition monitoring techniques.
condition-based, gas turbines, diagnostics,↗
Chelation ion chromatography as an automated, and cost-effective analytical technique for REE determination: method development and applications
Rare earth elements (REEs), as critical minerals, have important uses in modern energy and technologies, yet are vulnerable to potential supply chain disruptions. To establish domestic REE supply chain, efficient REE detection methods for resource characterization and mineral processing will be needed to accelerate innovations for domestic REE recovery. This study developed a rapid, novel, and cost-effective for REE detection method using ion chromatography (IC) for aqueous samples. Various REE-targeted eluent gradients and post-column agent compositions were tested on the chelation ion chromatography (CIC) with UV-vis detector for optimal separation and quantification of REEs within approximately 20 min. The single-channel pump to deliver the post-column solution to UV-vis detector was replaced with a 4-channel gradient pump, to increase operation and maintenance efficiencies. After method optimization, resulting calibration curves for more than ten REEs achieved high coefficients of determination (R2>0.999) and low relatively standard deviations (below 3.24%), demonstrating sub-ppm level detection limits (0.0897 to 0.1149 mg/L). The reliability of the CIC method was validated through comparison with inductively coupled plasma mass spectrometry (ICP-MS), showing strong agreement in REE recovery from certified standards. The impact of metal ions and salts on REE recovery using CIC was also systematically investigated. CIC consistently exhibited reliable performance in the presence of salt solutions such as NaCl and Na₂SO₄ (up to 10,000 mg/L). Our study also found the presence of high concentrations of Al ions (at 10,000 mg/L) significantly influenced REE determination, and elevated concentrations of Ca ions affected the recovery of specific REEs, including La, Ce, and Pr. The CIC method was further tested on REE-containing eluents from solvent extraction tests out of fly ash leachates. REE detection from these real processing fluids were reported to achieve 90% to 100% recovery rate from our IC method, compared to ICP-MS results. This study underscores the potential of CIC as a reliable and efficient alternative for REE determination in complex matrices. It also highlights the importance of minimizing select interfering metal ions in solutions to ensure accurate results. The REE CIC method presents a promising, low-maintenance, salt-tolerant, and cost-effective alternative to traditional analytical methods for REE analysis.
detection of rare earth elements (REE)↗
HOMP (Hybrid Operation and Maintenance Platform) [SWR-22-81]
The HOMP software module is contained within NREL's Hybrid Optimization and Performance Platform (HOPP) at this URL: https://github.com/NREL/HOPP/tree/feature/HOMP. HOMP is a python-based software module which can be used concurrently with the Hybrid Optimization and Performance Platform (HOPP) to model, simulate, and optimize degradation, reliability, and operations and maintenance of hybrid power plant components. The program currently models lithium ion battery, PEM electrolyzer, wind turbine, and solar PV array components, which enables users to understand the design and operation tradeoffs of hybrid power plants. For instance, HOMP enables users to answer questions like: how large does a battery bank need to be to achieve optimal charge/discharge rates for performance and reliability? How does plant design change for different objectives (e.g., profit versus resilience)? Under what conditions is it better to produce electricity versus hydrogen? How do we optimally control hybrid power plants to reduce downtime and increase performance?
Clark, Caitlyn↗
Automation of debris removal and resurfacing of insulators in terawatt pulsed power systems using state of the art laser technology
The increasing complexity and scale of pulsed power systems necessitate effective maintenance strategies to ensure optimal performance and safety. This report investigates the automation of debris removal and resurfacing of insulators in terawatt pulsed power systems using advanced laser cleaning technologies. The motivation for this research stems from the limitations of current manual cleaning methods, which are labor-intensive and pose health risks due to hazardous materials. The study addresses the problem of surface flashover, a significant issue affecting insulator performance, by evaluating two innovative cleaning techniques: Pulsed Laser Cleaning (PLC) and Flash Lamp Annealing (FLA). Experimental results demonstrate that PLC effectively restores the dielectric strength of Rexolite insulators, while FLA shows limited success. The findings highlight the potential for automated cleaning solutions to enhance safety and efficiency in insulator maintenance, paving the way for future advancements in pulsed power technology.
42 ENGINEERING↗
Predictive Data Analytics Framework Using Advanced Test Reactor Acoustic Data
Although a nuclear reactor is a hostile environment for sensing and electrical communications, the reactor core is amenable to acoustic communication. An acoustic measurement infrastructure (AMI) has been installed at the Advanced Test Reactor (ATR) nozzle trench area to record acoustic signals that has the ability to capture different operating regime of the reactor. This AMI includes ATR in-pile structural components, coolant, acoustic receivers, primary coolant pumps (PCP) as signal sources, a data acquisition system, and signal-processing algorithms, enabling real-time. This report will discusses development of recursive Fast Fourier Transform approach to process in real-time acoustic signals, application of short time Fast Fourier Transform to the ATR brush data to understand the vibration level and to develop spectrograms for different primary coolant pump combinations. The combination of primary coolant pumps for normal and power axial locator mechanism of ATR are different and generates different signatures. These acoustic signatures were used to develop machine learning approaches to automatically classify different operating regimes. This lay the foundation for predictive analytic framework that can be leverage by ATR to optimize their operation and maintenance. The path forward involves continued engagement with ATR and expanded implementation of AMI and predictive framework at ATR and other facilities within INL and at other experimental reactors.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
CRADA Number NFE-24-10110 with Qubit Engineering Inc. (CRADA Final Report)
Over the past year, the Qubit Engineering team has pushed the frontiers of power‑grid optimization, working in close collaboration with Oak Ridge National Laboratory (ORNL) and the Tennessee Valley Authority (TVA). Their progress is reflected in three newly submitted conference papers, “Unified Relational GNN Architecture for AC Optimal Power Flow Calculations in Electric Grids,” “Graph‑Based Attention Mechanisms for Solving the AC Optimal Power Flow Problem in Electrical‑Power Networks,” and “Enhanced Power‑Grid Maintenance Planning and Quantum‑Inspired Combinatorial Prospects.” These publications showcase state‑of‑the‑art graph‑neural‑network methods for AC‑OPF and novel quantum‑inspired heuristics for maintenance scheduling. Beyond the academic results, the Qubit team has converted the research into two production‑grade tools built on TVA data: Neuro‑Grid, an AI‑driven power‑flow simulator that provides instant, interactive full‑grid load‑flow visualizations, and Quanta‑Grid, a quantum‑inspired maintenance‑scheduling engine to support logistics optimization for power utilities. Together, these advances demonstrate how Qubit’s partnership with ORNL and TVA is delivering practical, physics‑grounded analytics for next‑generation grid management.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Distributed operating system for NASA ground stations
NASA ground stations are characterized by ever changing support requirements, so application software is developed and modified on a continuing basis. A distributed operating system was designed to optimize the generation and maintenance of those applications. Unusual features include automatic program generation from detailed design graphs, on-line software modification in the testing phase, and the incorporation of a relational database within a real-time, distributed system.
Doyle, John F.↗
Global Precipitation Measurement - Report 9 Core Coverage Trade Space Analysis
This paper summarizes the GPM-Core coverage trade space analysis. The goal of this analysis was to determine the GPM-Core sensitivity to changes in altitude and inclination for the three onboard instruments: the radiometer, the KU band radar and the KA band radar. This study will enable a better choice of the nominal GPM-Core orbit as well as the optimal size of the maintenance box (+/-1 km, +/-5 km..). For this work, we used two different figures-of-merit: (1) the time required to cover 100% of the +/-65 deg latitude band and (2) the coverage obtained for a given propagation time (7 days and 30 days). The first figure-of-merit is used for the radiometer as it has a sensor cone half-angle between 3 to 5 times bigger than the radars. Thus, we anticipate that for this instrument the period of the orbit (i.e. altitude) will be the main driver and that the 100% coverage value will be reached within less than a week. The second figure-of-merit is used for the radar instruments as they have small sensor cone half-angle and will, in some cases, never reach the 100% coverage threshold point.
Mailhe, Laurie↗
Economic Risk-Informed Maintenance Planning and Asset Management (Final Report)
The proposed work will provide a holistic framework for cost-minimizing risk-informed maintenance planning, including inspection, in light water reactors (LWRs). Specifically, we develop a two-tier framework that (a) coarsely minimizes the total maintenance cost during the remaining normal operating cycle of the plant prior to the next scheduled outage (long-term), subject to safety requirements, and (b) uses the outputs of the first model to develop a secondary optimization model to finely schedule maintenance activities to maximize the financial impact of these activities in the next week (short-term).
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
IMIS: Integrated Maintenance Information System. A maintenance information delivery concept
The Integrated Maintenance Information System (IMIS) will optimize the use of available manpower, enhance technical performance, improve training, and reduce the support equipment and documentation needed for deployment. It will serve as the technician's single, integrated source of all the technical information required to perform modern aircraft maintenance.
Vonholle, Joseph C.↗
Investigation of Fe-Ni Battery/Module for Grid Service Duty Cycles
Iron–nickel (Fe-Ni) batteries are renowned for their durability and resilience against overcharging and operating temperatures. However, they encounter challenges in achieving widespread adoption for energy storage applications due to their low efficiency and the need for regular maintenance and electrolyte replacement, which adds to maintenance costs. This study evaluates and demonstrates the capabilities of Fe-Ni batteries for participating in grid energy storage applications. Stable performance was observed frequency regulation (FR) testing at 100% and 50% state of charge (SOC)s, while at 50% SOC, there was a 14% increase in efficiency compared to 100% SOC. Although 25% SOC achieved higher efficiency, limited cyclability was observed due to reaching the discharge cutoff voltage. Optimal SOC selection, battery monitoring, maintenance, and appropriate charging strategies of Fe-Ni batteries seem to be crucial for their FR applications. Fe-Ni batteries exhibit stable peak shaving (PS) results, indicating their suitability and reliability under various load conditions for PS testing. Extended cycling tests confirm their potential for long-term grid-scale energy storage, enhancing their appeal for PS and FR applications.
25 ENERGY STORAGE↗
A review of artificial intelligence applications in manufacturing operations
Abstract Artificial intelligence (AI) and machine learning (ML) can improve manufacturing efficiency, productivity, and sustainability. However, using AI in manufacturing also presents several challenges, including issues with data acquisition and management, human resources, infrastructure, as well as security risks, trust, and implementation challenges. For example, getting the data needed to train AI models can be difficult for rare events or costly for large datasets that need labeling. AI models can also pose security risks when integrated into industrial control systems. In addition, some industry players may be hesitant to use AI due to a lack of trust or understanding of how it works. Despite these challenges, AI has the potential to be extremely helpful in manufacturing, particularly in applications such as predictive maintenance, quality assurance, and process optimization. It is important to consider the specific needs and capabilities of each manufacturing scenario when deciding whether and how to use AI in manufacturing. This review identifies current developments, challenges, and future directions in AI/ML relevant to manufacturing, with the goal of improving understanding of AI/ML technologies available for solving manufacturing problems, providing decision‐support for prioritizing and selecting appropriate AI/ML technologies, and identifying areas where further research can yield transformational returns for the industry. Early experience suggests that AI/ML can have significant cost and efficiency benefits in manufacturing, especially when combined with the ability to capture enormous amounts of data from manufacturing systems.
Plathottam, Siby Jose↗
Air Brayton Solar Receiver, phase 1
A six month analysis and conceptual design study of an open cycle Air Brayton Solar Receiver (ABSR) for use on a tracking, parabolic solar concentrator are discussed. The ABSR, which includes a buffer storage system, is designed to provide inlet air to a power conversion unit. Parametric analyses, conceptual design, interface requirements, and production cost estimates are described. The design features were optimized to yield a zero maintenance, low cost, high efficiency concept that will provide a 30 year operational life.
Zimmerman, D. K.↗
Cell contact as an independent factor modulating cardiac myocyte hypertrophy and survival in long-term primary culture
Cardiac myocytes maintained in cell culture develop hypertrophy both in response to mechanical loading as well as to receptor-mediated signaling mechanisms. However, it has been shown that the hypertrophic response to these stimuli may be modulated through effects of intercellular contact achieved by maintaining cells at different plating densities. In this study, we show that the myocyte plating density affects not only the hypertrophic response and features of the differentiated phenotype of isolated adult myocytes, but also plays a significant role influencing myocyte survival in vitro. The native rod-shaped phenotype of freshly isolated adult myocytes persists in an environment which minimizes myocyte attachment and spreading on the substratum. However, these conditions are not optimal for long-term maintenance of cultured adult cardiac myocytes. Conditions which promote myocyte attachment and spreading on the substratum, on the other hand, also promote the re-establishment of new intercellular contacts between myocytes. These contacts appear to play a significant role in the development of spontaneous activity, which enhances the redevelopment of highly differentiated contractile, junctional, and sarcoplasmic reticulum structures in the cultured adult cardiomyocyte. Although it has previously been shown that adult cardiac myocytes are typically quiescent in culture, the addition of beta-adrenergic agonists stimulates beating and myocyte hypertrophy, and thereby serves to increase the level of intercellular contact as well. However, in densely-plated cultures with intrinsically high levels of intercellular contact, spontaneous contractile activity develops without the addition of beta-adrenergic agonists. In this study, we compare the function, morphology, and natural history of adult feline cardiomyocytes which have been maintained in cultures with different levels of intercellular contact, with and without the addition of beta-adrenergic agonists. Intercellular contact, communication, and transmission of contractile forces between myocytes appears to play a primary role in remodeling the 2-dimensional cell layer into a parallel alignment of elongated myocytes with highly developed intercalated disk-like junctions. This highly differentiated state is very stable, and cultures which achieve this state exhibit significantly greater longevity than more sparsely plated myocytes. These myocytes typically continue beating, and survive from 6 to more than 12 weeks in culture. When this level of contact and differentiation are not achieved, even among beta-adrenergic stimulated myocytes, contractile activity is not sustained, myofibrils atrophy, there is little or no development of junctional complexes, and the period of myocyte viability is typically no more than 5 weeks in vitro.
Non-NASA Center↗