Review of Markov models for maintenance optimization in the context of offshore wind

The offshore environment poses a number of challenges to wind farm operators. Harsher climatic conditions typically result in lower reliability while challenges in accessibility make maintenance difficult. One of the ways to improve availability is to optimize the Operation and Maintenance (O&M) actions such as scheduled, corrective and proactive maintenance. Many authors have attempted to model or optimize O&M through the use of Markov models. Two examples of Markov models, Hidden Markov Models (HMMs) and Partially Observable Markov Decision Processes (POMDPs) are investigated in this paper. In general, Markov models are a powerful statistical tool, which has been successfully applied for component diagnostics, prognostics and maintenance optimization across a range of industries. This paper discusses the suitability of these models to the offshore wind industry. Existing models which have been created for the wind industry are critically reviewed and discussed. As there is little evidence of widespread application of these models, this paper aims to highlight the key factors required for successful application of Markov models to practical problems. From this, the paper identifies the necessary theoretical and practical gaps that must be resolved in order to gain broad acceptance of Markov models to support O&M decision making in the offshore wind industry

Diagnostics and prognostics utilising dynamic Bayesian networks applied to a wind turbine gearbox

The UK has the largest installed capacity of offshore wind and this is set to increase significantly in future years. The difficulty in conducting maintenance offshore leads to increased operation and maintenance costs compared to onshore but with better condition monitoring and preventative maintenance strategies these costs could be reduced. In this paper an on-line condition monitoring system is created that is capable of diagnosing machine component conditions based on an array of sensor readings. It then informs the operator of actions required. This simplifies the role of the operator and the actions required can be optimised within the program to minimise costs. The program has been applied to a gearbox oil testbed to demonstrate its operational suitability. In addition a method for determining the most cost effective maintenance strategy is examined. This method uses a Dynamic Bayesian Network to simulate the degradation of wind turbine components, effectively acting as a prognostics tool, and calculates the cost of various preventative maintenance strategies compared to purely corrective maintenance actions. These methods are shown to reduce the cost of operating wind turbines in the offshore environment

Multidimensional prognostics for rotating machinery: A review

open access articleDetermining prognosis for rotating machinery could potentially reduce maintenance costs and improve safety and avail- ability. Complex rotating machines are usually equipped with multiple sensors, which enable the development of multidi- mensional prognostic models. By considering the possible synergy among different sensor signals, multivariate models may provide more accurate prognosis than those using single-source information. Consequently, numerous research papers focusing on the theoretical considerations and practical implementations of multivariate prognostic models have been published in the last decade. However, only a limited number of review papers have been written on the subject. This article focuses on multidimensional prognostic models that have been applied to predict the failures of rotating machinery with multiple sensors. The theory and basic functioning of these techniques, their relative merits and draw- backs and how these models have been used to predict the remnant life of a machine are discussed in detail. Furthermore, this article summarizes the rotating machines to which these models have been applied and discusses future research challenges. The authors also provide seven evaluation criteria that can be used to compare the reviewed techniques. By reviewing the models reported in the literature, this article provides a guide for researchers considering prognosis options for multi-sensor rotating equipment

Condition-based maintenance—an extensive literature review

This paper presents an extensive literature review on the field of condition-based maintenance (CBM). The paper encompasses over 4000 contributions, analysed through bibliometric indicators and meta-analysis techniques. The review adopts Factor Analysis as a dimensionality reduction, concerning the metric of the co-citations of the papers. Four main research areas have been identified, able to delineate the research field synthetically, from theoretical foundations of CBM; (i) towards more specific implementation strategies (ii) and then specifically focusing on operational aspects related to (iii) inspection and replacement and (iv) prognosis. The data-driven bibliometric results have been combined with an interpretative research to extract both core and detailed concepts related to CBM. This combined analysis allows a critical reflection on the field and the extraction of potential future research directions

Process fault prediction and prognosis based on a hybrid technique

The present study introduces a novel hybrid methodology for fault detection and diagnosis (FDD) and fault prediction and prognosis (FPP). The hybrid methodology combines both data-driven and process knowledge driven techniques. The Hidden Markov Model (HMM) and the auxiliary codes detect and predict the abnormalities based on process history while the Bayesian Network (BN) diagnoses the root cause of the fault based on process knowledge. In the first step, the system performance is evaluated for fault detection and diagnosis and in the second step, prediction and prognosis are evaluated. In both cases, an HMM trained with Normal Operating Condition data is used to determine the log-likelihoods (LL) of each process history data string. It is then used to develop the Conditional Probability Tables of BN while the structure of BN is developed based on process knowledge. Abnormal behaviour of the system is identified through HMM. The time of detection of an abnormality, respective LL value, and the probabilities of being in the process condition at the time of detection are used to generate the likelihood evidence to BN. The updated BN is then used to diagnose the root cause by considering the respective changes of the probabilities. Performance of the new technique is validated with published data of Tennessee Eastman Process. Eight of the ten selected faults were successfully detected and diagnosed. The same set of faults were predicted and prognosed accurately at different levels of maximum added noise

Vehicle level health assessment through integrated operational scalable prognostic reasoners

Today’s aircraft are very complex in design and need constant monitoring of the systems to establish the overall health status. Integrated Vehicle Health Management (IVHM) is a major component in a new future asset management paradigm where a conscious effort is made to shift asset maintenance from a scheduled based approach to a more proactive and predictive approach. Its goal is to maximize asset operational availability while minimising downtime and the logistics footprint through monitoring deterioration of component conditions. IVHM involves data processing which comprehensively consists of capturing data related to assets, monitoring parameters, assessing current or future health conditions through prognostics and diagnostics engine and providing recommended maintenance actions. The data driven prognostics methods usually use a large amount of data to learn the degradation pattern (nominal model) and predict the future health. Usually the data which is run-to-failure used are accelerated data produced in lab environments, which is hardly the case in real life. Therefore, the nominal model is far from the present condition of the vehicle, hence the predictions will not be very accurate. The prediction model will try to follow the nominal models which mean more errors in the prediction, this is a major drawback of the data driven techniques. This research primarily presents the two novel techniques of adaptive data driven prognostics to capture the vehicle operational scalability degradation. Secondary the degradation information has been used as a Health index and in the Vehicle Level Reasoning System (VLRS). Novel VLRS are also presented in this research study. The research described here proposes a condition adaptive prognostics reasoning along with VLRS

Evolving Clustering Algorithms And Their Application For Condition Monitoring, Diagnostics, & Prognostics

Applications of Condition-Based Maintenance (CBM) technology requires effective yet generic data driven methods capable of carrying out diagnostics and prognostics tasks without detailed domain knowledge and human intervention. Improved system availability, operational safety, and enhanced logistics and supply chain performance could be achieved, with the widespread deployment of CBM, at a lower cost level. This dissertation focuses on the development of a Mutual Information based Recursive Gustafson-Kessel-Like (MIRGKL) clustering algorithm which operates recursively to identify underlying model structure and parameters from stream type data. Inspired by the Evolving Gustafson-Kessel-like Clustering (eGKL) algorithm, we applied the notion of mutual information to the well-known Mahalanobis distance as the governing similarity measure throughout. This is also a special case of the Kullback-Leibler (KL) Divergence where between-cluster shape information (governed by the determinant and trace of the covariance matrix) is omitted and is only applicable in the case of normally distributed data. In the cluster assignment and consolidation process, we proposed the use of the Chi-square statistic with the provision of having different probability thresholds. Due to the symmetry and boundedness property brought in by the mutual information formulation, we have shown with real-world data that the algorithm’s performance becomes less sensitive to the same range of probability thresholds which makes system tuning a simpler task in practice. As a result, improvement demonstrated by the proposed algorithm has implications in improving generic data driven methods for diagnostics, prognostics, generic function approximations and knowledge extractions for stream type of data. The work in this dissertation demonstrates MIRGKL’s effectiveness in clustering and knowledge representation and shows promising results in diagnostics and prognostics applications

Intelligent maintenance management in a reconfigurable manufacturing environment using multi-agent systems

Thesis (M. Tech.) -- Central University of Technology, Free State, 2010Traditional corrective maintenance is both costly and ineffective. In some situations it is more cost effective to replace a device than to maintain it; however it is far more likely that the cost of the device far outweighs the cost of performing routine maintenance. These device related costs coupled with the profit loss due to reduced production levels, makes this reactive maintenance approach unacceptably inefficient in many situations. Blind predictive maintenance without considering the actual physical state of the hardware is an improvement, but is still far from ideal. Simply maintaining devices on a schedule without taking into account the operational hours and workload can be a costly mistake. The inefficiencies associated with these approaches have contributed to the development of proactive maintenance strategies. These approaches take the device health state into account. For this reason, proactive maintenance strategies are inherently more efficient compared to the aforementioned traditional approaches. Predicting the health degradation of devices allows for easier anticipation of the required maintenance resources and costs. Maintenance can also be scheduled to accommodate production needs. This work represents the design and simulation of an intelligent maintenance management system that incorporates device health prognosis with maintenance schedule generation. The simulation scenario provided prognostic data to be used to schedule devices for maintenance. A production rule engine was provided with a feasible starting schedule. This schedule was then improved and the process was determined by adhering to a set of criteria. Benchmarks were conducted to show the benefit of optimising the starting schedule and the results were presented as proof. Improving on existing maintenance approaches will result in several benefits for an organisation. Eliminating the need to address unexpected failures or perform maintenance prematurely will ensure that the relevant resources are available when they are required. This will in turn reduce the expenditure related to wasted maintenance resources without compromising the health of devices or systems in the organisation

Towards multi-model approaches to predictive maintenance: A systematic literature survey on diagnostics and prognostics

The use of a modern technological system requires a good engineering approach, optimized operations, and proper maintenance in order to keep the system in an optimal state. Predictive maintenance focuses on the organization of maintenance actions according to the actual health state of the system, aiming at giving a precise indication of when a maintenance intervention will be necessary. Predictive maintenance is normally implemented by means of specialized computational systems that incorporate one of several models to fulfil diagnostics and prognostics tasks. As complexity of technological systems increases over time, single-model approaches hardly fulfil all functions and objectives for predictive maintenance systems. It is increasingly common to find research studies that combine different models in multi-model approaches to overcome complexity of predictive maintenance tasks, considering the advantages and disadvantages of each single model and trying to combine the best of them. These multi-model approaches have not been extensively addressed by previous review studies on predictive maintenance. Besides, many of the possible combinations for multi-model approaches remain unexplored in predictive maintenance applications; this offers a vast field of opportunities when architecting new predictive maintenance systems. This systematic survey aims at presenting the current trends in diagnostics and prognostics giving special attention to multi-model approaches and summarizing the current challenges and research opportunities