Nuclear at Argonne: PRO-AID - An Advanced Physics-Based System Health Monitoring Software Suite

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The Department of Energy’s Argonne National Laboratory drives innovation to solve the world’s most pressing challenges. In the 1990s, Argonne pioneered the Multivariate State Estimation Technique (MSET), a breakthrough in condition monitoring that became an industry standard and was later commercialized.

Industrial operations face persistent challenges in early fault detection and predictive maintenance. Many existing alarm systems lack specificity, leading to missed or false diagnoses that result in costly downtime. Purely data-driven machine learning models are expensive to maintain and require frequent updates. Additionally, sensor failures and system reconfigurations disrupt monitoring capabilities, reducing operational reliability. A more robust and adaptable approach is needed to address these challenges.

To meet this need, Argonne developed PRO-AID, an advanced diagnostic tool that redefines industrial monitoring and predictive maintenance. PRO-AID performs real-time monitoring and diagnostics using automated reasoning and a physics-based digital twin of the system. This innovative approach enables more accurate anomaly detection and system insights, ensuring greater reliability and efficiency. By integrating physics-based modeling with machine learning, PRO-AID enhances fault detection and system optimization, continuing Argonne’s legacy of innovation in industrial diagnostics.

Unlike purely data-driven machine learning applications, PRO-AID dynamically adapts to system changes, reducing maintenance costs and improving fault identification. The software provides ranked fault probabilities, self-learns model parameters during operation, and seamlessly integrates with industrial platforms. Lessons learned from MSET’s development and widespread deployment informed PRO-AID’s design, allowing it to overcome the limitations of earlier-generation monitoring tools. Successfully applied to diagnose anomalies in industrial facilities, PRO-AID has also been validated through human factors studies conducted with power plant operators, ensuring its effectiveness in real-world scenarios.

Successfully demonstrated in nuclear energy systems and undergoing further testing at Argonne’s Mechanisms Engineering Test Loop (METL) facility, PRO-AID is ready for deployment. With an intuitive graphical user interface (GUI) for broad industry compatibility and integration with large language models (LLMs) for natural language communication, PRO-AID is a game-changer. By enabling precise fault detection, reducing maintenance costs, and optimizing system performance, PRO-AID offers a transformative solution for industries seeking the next generation of intelligent monitoring technology.

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ABOUT ARGONNE

Argonne National Laboratory seeks solutions to pressing national problems in science and technology by conducting leading-edge basic and applied research in virtually every scientific discipline. Argonne is managed by UChicago Argonne, LLC for the U.S. Department of Energy’s Office of Science.

The U.S. Department of Energy’s Office of Science is the single largest supporter of basic research in the physical sciences in the United States and is working to address some of the most pressing challenges of our time. For more information, visit the Office of Science website.