A Literature Review of Fault Diagnosis Based on Ensemble Learning

The accuracy of fault diagnosis is an important indicator to ensure the reliability of key equipment systems. Ensemble learning integrates different weak learning methods to obtain stronger learning and has achieved remarkable results in the field of fault diagnosis. This paper reviews the recent research on ensemble learning from both technical and field application perspectives. The paper summarizes 87 journals in recent web of science and other academic resources, with a total of 209 papers. It summarizes 78 different ensemble learning based fault diagnosis methods, involving 18 public datasets and more than 20 different equipment systems. In detail, the paper summarizes the accuracy rates, fault classification types, fault datasets, used data signals, learners (traditional machine learning or deep learning-based learners), ensemble learning methods (bagging, boosting, stacking and other ensemble models) of these fault diagnosis models. The paper uses accuracy of fault diagnosis as the main evaluation metrics supplemented by generalization and imbalanced data processing ability to evaluate the performance of those ensemble learning methods. The discussion and evaluation of these methods lead to valuable research references in identifying and developing appropriate intelligent fault diagnosis models for various equipment. This paper also discusses and explores the technical challenges, lessons learned from the review and future development directions in the field of ensemble learning based fault diagnosis and intelligent maintenance

Condition Monitoring and Fault Diagnosis of Fluid Machines in Process Industries

Condition Monitoring (CM) of fluid machines plays a critical role in maintaining efficient productivity in many processing industries. Conventional vibration techniques generally provide more localised information with the need for many sensors, associated data acquiring and processing efforts, which are difficult for system deployment and are reluctantly accepted by those industries, for example paper mills and food production lines making marginal profits. To find adequate CM techniques for such industries this research investigates a new cost- effective scheme of implementing CM, which combines the high diagnostic capability of using Surface Vibration (SV) with the global detection capability of using the Instantaneous Angular Speed (IAS) measurements and Airborne Sound (AS). To address specific techniques involved in the scheme, this research is arranged in three consecutive Phases: Phase I is the technical evaluation; Phase II is the field implementation practices and Phase III is the application of AS through Convolution Neural Networks (CNN). In Phase I, widely used reciprocating compressor is investigated numerically and experimentally, which clarifies the performances of SV, IAS, AS, pressure and motor current in a quantitative way for differentiating common faults such as leakages happening in valves and intercoolers, faulty motor drives and mechanical transmission systems. It paves the foundations for the field implementation in Phase II. In Phase II, this novel scheme is realised on three sets of vacuum pumps in a paper mill. Based on an analytic study of dynamic responses to common faults on these pumps, a field test was conducted to verify the feasibility of the scheme and the preliminary study shows that airborne sound can show the relative spectral components for each machine to a good degree of accuracy. Knowledge gained from the preceding phases of study is now applied to Phase III. New techniques based on airborne signal differences through CNN have been demonstrated to give a good indication of the sound propagation and location of noise sources under all operating discharge pressure conditions at 100% validation accuracy, proving that the state of the art deep leaning approaches can be used to deal with complicated acoustic data

Predictive Maintenance of Critical Equipment for Floating Liquefied Natural Gas Liquefaction Process

Predictive Maintenance of Critical Equipment for Liquefied Natural Gas Liquefaction Process Meeting global energy demand is a massive challenge, especially with the quest of more affinity towards sustainable and cleaner energy. Natural gas is viewed as a bridge fuel to a renewable energy. LNG as a processed form of natural gas is the fastest growing and cleanest form of fossil fuel. Recently, the unprecedented increased in LNG demand, pushes its exploration and processing into offshore as Floating LNG (FLNG). The offshore topsides gas processes and liquefaction has been identified as one of the great challenges of FLNG. Maintaining topside liquefaction process asset such as gas turbine is critical to profitability and reliability, availability of the process facilities. With the setbacks of widely used reactive and preventive time-based maintenances approaches, to meet the optimal reliability and availability requirements of oil and gas operators, this thesis presents a framework driven by AI-based learning approaches for predictive maintenance. The framework is aimed at leveraging the value of condition-based maintenance to minimises the failures and downtimes of critical FLNG equipment (Aeroderivative gas turbine). In this study, gas turbine thermodynamics were introduced, as well as some factors affecting gas turbine modelling. Some important considerations whilst modelling gas turbine system such as modelling objectives, modelling methods, as well as approaches in modelling gas turbines were investigated. These give basis and mathematical background to develop a gas turbine simulated model. The behaviour of simple cycle HDGT was simulated using thermodynamic laws and operational data based on Rowen model. Simulink model is created using experimental data based on Rowen’s model, which is aimed at exploring transient behaviour of an industrial gas turbine. The results show the capability of Simulink model in capture nonlinear dynamics of the gas turbine system, although constraint to be applied for further condition monitoring studies, due to lack of some suitable relevant correlated features required by the model. AI-based models were found to perform well in predicting gas turbines failures. These capabilities were investigated by this thesis and validated using an experimental data obtained from gas turbine engine facility. The dynamic behaviours gas turbines changes when exposed to different varieties of fuel. A diagnostics-based AI models were developed to diagnose different gas turbine engine’s failures associated with exposure to various types of fuels. The capabilities of Principal Component Analysis (PCA) technique have been harnessed to reduce the dimensionality of the dataset and extract good features for the diagnostics model development. Signal processing-based (time-domain, frequency domain, time-frequency domain) techniques have also been used as feature extraction tools, and significantly added more correlations to the dataset and influences the prediction results obtained. Signal processing played a vital role in extracting good features for the diagnostic models when compared PCA. The overall results obtained from both PCA, and signal processing-based models demonstrated the capabilities of neural network-based models in predicting gas turbine’s failures. Further, deep learning-based LSTM model have been developed, which extract features from the time series dataset directly, and hence does not require any feature extraction tool. The LSTM model achieved the highest performance and prediction accuracy, compared to both PCA-based and signal processing-based the models. In summary, it is concluded from this thesis that despite some challenges related to gas turbines Simulink Model for not being integrated fully for gas turbine condition monitoring studies, yet data-driven models have proven strong potentials and excellent performances on gas turbine’s CBM diagnostics. The models developed in this thesis can be used for design and manufacturing purposes on gas turbines applied to FLNG, especially on condition monitoring and fault detection of gas turbines. The result obtained would provide valuable understanding and helpful guidance for researchers and practitioners to implement robust predictive maintenance models that will enhance the reliability and availability of FLNG critical equipment.Petroleum Technology Development Funds (PTDF) Nigeri

Fault Detection and RUL Estimation for Railway HVAC Systems Using a Hybrid Model-Based Approach

Heating, ventilation, and air conditioning (HVAC) systems installed in a passenger train carriage are critical systems, whose failures can affect people or the environment. This, together with restrictive regulations, results in the replacement of critical components in initial stages of degradation, as well as a lack of data on advanced stages of degradation. This paper proposes a hybrid model-based approach (HyMA) to overcome the lack of failure data on a HVAC system installed in a passenger train carriage. The proposed HyMA combines physics-based models with data-driven models to deploy diagnostic and prognostic processes for a complex and critical system. The physics-based model generates data on healthy and faulty working conditions; the faults are generated in different levels of degradation and can appear individually or together. A fusion of synthetic data and measured data is used to train, validate, and test the proposed hybrid model (HyM) for fault detection and diagnostics (FDD) of the HVAC system. The model obtains an accuracy of 92.60%. In addition, the physics-based model generates run-to-failure data for the HVAC air filter to develop a remaining useful life (RUL) prediction model, the RUL estimations performed obtained an accuracy in the range of 95.21–97.80% Both models obtain a remarkable accuracy. The development presented will result in a tool which provides relevant information on the health state of the HVAC system, extends its useful life, reduces its life cycle cost, and improves its reliability and availability; thus enhancing the sustainability of the system.Research was funded by the Basque Government, through ELKARTEK (ref. KK-2020/00049) funding grant

Fault Diagnosis Of Sensor And Actuator Faults In Multi-Zone Hvac Systems

Globally, the buildings sector accounts for 30% of the energy consumption and more than 55% of the electricity demand. Specifically, the Heating, Ventilation, and Air Conditioning (HVAC) system is the most extensively operated component and it is responsible alone for 40% of the final building energy usage. HVAC systems are used to provide healthy and comfortable indoor conditions, and their main objective is to maintain the thermal comfort of occupants with minimum energy usage. HVAC systems include a considerable number of sensors, controlled actuators, and other components. They are at risk of malfunctioning or failure resulting in reduced efficiency, potential interference with the execution of supervision schemes, and equipment deterioration. Hence, Fault Diagnosis (FD) of HVAC systems is essential to improve their reliability, efficiency, and performance, and to provide preventive maintenance. In this thesis work, two neural network-based methods are proposed for sensor and actuator faults in a 3-zone HVAC system. For sensor faults, an online semi-supervised sensor data validation and fault diagnosis method using an Auto-Associative Neural Network (AANN) is developed. The method is based on the implementation of Nonlinear Principal Component Analysis (NPCA) using a Back-Propagation Neural Network (BPNN) and it demonstrates notable capability in sensor fault and inaccuracy correction, measurement noise reduction, missing sensor data replacement, and in both single and multiple sensor faults diagnosis. In addition, a novel on-line supervised multi-model approach for actuator fault diagnosis using Convolutional Neural Networks (CNNs) is developed for single actuator faults. It is based a data transformation in which the 1-dimensional data are configured into a 2-dimensional representation without the use of advanced signal processing techniques. The CNN-based actuator fault diagnosis approach demonstrates improved performance capability compared with the commonly used Machine Learning-based algorithms (i.e., Support Vector Machine and standard Neural Networks). The presented schemes are compared with other commonly used HVAC fault diagnosis methods for benchmarking and they are proven to be superior, effective, accurate, and reliable. The proposed approaches can be applied to large-scale buildings with additional zones

Assessment of monthly rain fade in the equatorial region at C & KU-band using measat-3 satellite links

C & Ku-band satellite communication links are the most commonly used for equatorial satellite communication links. Severe rainfall rate in equatorial regions can cause a large rain attenuation in real compared to the prediction. ITU-R P. 618 standards are commonly used to predict satellite rain fade in designing satellite communication network. However, the prediction of ITU-R is still found to be inaccurate hence hinder a reliable operational satellite communication link in equatorial region. This paper aims to provide an accurate insight by assessment of the monthly C & Ku-band rain fade performance by collecting data from commercial earth stations using C band and Ku-band antenna with 11 m and 13 m diameter respectively. The antennas measure the C & Ku-band beacon signal from MEASAT-3 under equatorial rain conditions. The data is collected for one year in 2015. The monthly cumulative distribution function is developed based on the 1-year data. RMSE analysis is made by comparing the monthly measured data of C-band and Ku-band to the ITU-R predictions developed based on ITU-R’s P.618, P.837, P.838 and P.839 standards. The findings show that Ku-band produces an average of 25 RMSE value while the C-band rain attenuation produces an average of 2 RMSE value. Therefore, the ITU-R model still under predicts the rain attenuation in the equatorial region and this call for revisit of the fundamental quantity in determining the rain fade for rain attenuation to be re-evaluated

NEXT GENERATION HEAT PUMP SYSTEM EVALUATION METHODOLOGIES

Energy consumption of heat pump (HP) systems plays a significant role in the global residential building energy sector. The conventional HP system evaluation method focused on the energy efficiency during a given time scale (e.g., hourly, seasonally, or annually). Nevertheless, these evaluation methods or test metrics are unable to fully reflect the thermodynamic characteristics of the system (e.g., the start-up process). In addition, previous researchers typically conducted HP field tests no longer than one year period. Only limited studies conducted the system performance tests over multiple years. Furthermore, the climate is changing faster than previously predicted beyond the irreversible and catastrophic tipping point. HP systems are the main contributor to global warming due to the increased demands but also can be a part of the solution by replacing fossil fuel burning heating systems. A holistic evaluation of the HP system’s global warming impact during its life cycle needs to account for the direct greenhouse gas (GHG) emissions from the refrigerant leakage, indirect GHG emissions from the power consumption and embodied equipment emissions. This dissertation leverages machine learning, deep learning, data digging, and Life Cycle Climate Performance (LCCP) approaches to develop next generation HP system evaluation methodologies with three thrusts: 1) field test data analysis, 2) data-driven modeling, and 3) enhanced life cycle climate performance (En-LCCP) analysis. This study made following observations: First, time-average performance metrics can save time in extensive data calculation, while quasi-steady-state performance metrics can elucidate some details of the studied system. Second, deep-learning-based algorithms have higher accuracy than conventional modeling approaches and can be used to analyze the system's dynamic performance. However, the complicated structure of the networks, numerous parameters needing optimization, and longer training time are the main challenges for these methods. Third, this dissertation improved current environmental impact evaluation method considering ambient conditions variation, local grid source structure, and next-generation low-GWP refrigerants, which led the LCCP results closer to reality and provided alternative methods for determining LCCP input parameters with limited-data cases. Future work could be studying the uncertainty within the deep learning networks and finding a general process for modeling settings. People may also develop a multi-objective optimization model for HP system design while considering both the LCCP and cost

Advances in Condition Monitoring, Optimization and Control for Complex Industrial Processes

The book documents 25 papers collected from the Special Issue “Advances in Condition Monitoring, Optimization and Control for Complex Industrial Processes”, highlighting recent research trends in complex industrial processes. The book aims to stimulate the research field and be of benefit to readers from both academic institutes and industrial sectors