Two-stage Residual Learning for Modelling Strength-Informed Optimisation of Thermal Systems

Real-time supervisory control of thermal energy distribution systems requires digital twins that are accurate, interpretable, and uncertainty-aware, yet remain data and computationally efficient. High-fidelity simulations alone are costly, while purely data-driven surrogates often lack robustness. To address these challenges, this work proposes an active learning (AL) framework that couples system-level Modelica simulations with four simpler physics-informed and data-driven surrogate modeling approaches: deterministic Sparse Identification of Nonlinear Dynamics with Control (SINDyC), its probabilistic multivariate-Gaussian extension (MvG-SINDyC), feedforward neural network (FNN), and gated recurrent unit (GRU) network. Tailored to each surrogate, model-specific AL query strategies are employed, including Mahalanobis-distance sampling in coefficient space for MvG-SINDyC and error-based sampling in prediction space for SINDyC, FNN, and GRU, allowing the learning process to prioritize dynamically informative trajectories. The proposed approach is demonstrated on the glycol heat exchanger (GHX) subsystem of the Thermal Energy Distribution System (TEDS) at Idaho National Laboratory. Across key GHX outputs--the bypass mass flow rate $\dot{m}_{\mathrm{GHX}}$ and heat transfer rate $Q_{\mathrm{GHX}}$-the AL framework achieves comparable predictive accuracy using as few as one-fifth of the simulation trajectories required by random sampling. Among the evaluated surrogates, the GRU achieves the highest predictive fidelity, while SINDyC remains the most computationally efficient and interpretable. The probabilistic MvG-SINDyC surrogate further enables uncertainty quantification and exhibits the largest computational gains under AL.

Artificial-intelligence surrogates can support second-by-second thermal-hydraulic forecasting, but models selected and frozen offline may become condition-locked once deployed outside their pretraining envelope. This study develops a guarded continual-adaptation framework for experimental thermal-hydraulic loop data in which role-separated agents - Monitor, Diagnosis, Adaptation, Safety-Auditor, and Orchestrator - diagnose error signatures, prioritize candidate model families, and review promotions, while deterministic champion-challenger gates and background shadow learning retain final authority over model replacement. Seven surrogate families were screened by blocked three-fold cross-validation, and a temporal Fourier neural operator was selected as the initial champion for 60-s-history-to-10-s-trajectory forecasting on two held-out transients, with three seeds per adaptive mode. Static deployment gave a channel-averaged MAE of 7.06 and a 56.8% warning-exceedance ratio; rule-based adaptation reduced MAE to 6.54, whereas shadow refresh alone remained close to Static. The MA-Full mode, in which the role-separated multi-agent council reviews every evaluated stream step, achieved the lowest mean error, 5.72, and 35.8% exceedance, corresponding to a 19.0% improvement over Static. Paired bootstrap intervals against Static excluded zero, although intervals among adaptive modes overlapped and the six paired units limit broad statistical claims. Validated promotions from the neural operator to Transformer and graph neural network indicate that logged, gate-controlled adaptation can support auditable surrogate evolution while deterministic gates retain deployment authority.

Neural surrogates are widely used in scientific machine learning for fast prediction of three-dimensional (3D) thermo-fluid fields. However, generating training data using conventional numerical solvers often incurs substantial computational and storage costs. We propose to train an attention graph neural network by minimizing the finite-volume method (FVM) residuals of the governing equations. These residuals are evaluated directly on the mesh, requiring no labeled data. We evaluate the trained surrogates against computational fluid dynamics (CFD) references and a data-supervised baseline across four scenarios. On the two steady-state benchmarks, the FVM-loss model achieves an all-field normalized root-mean-square error (nRMSE) of 2.3-2.8%. It demonstrates close agreement with the CFD references, including the buoyancy-energy coupling. On the two parametric transient cases, the FVM-loss model outperforms the supervised baseline in terms of accuracy, while avoiding the data-generation cost entirely. These results indicate that the FVM loss can provide a practical training signal for neural surrogates and reduce the model development cost.