The latent state hazard model, with application to wind turbine reliability

We present a new model for reliability analysis that is able to distinguish the latent internal vulnerability state of the equipment from the vulnerability caused by temporary external sources. Consider a wind farm where each turbine is running under the external effects of temperature, wind speed and direction, etc. The turbine might fail because of the external effects of a spike in temperature. If it does not fail during the temperature spike, it could still fail due to internal degradation, and the spike could cause (or be an indication of) this degradation. The ability to identify the underlying latent state can help better understand the effects of external sources and thus lead to more robust decision-making. We present an experimental study using SCADA sensor measurements from wind turbines in Italy.Comment: Published at http://dx.doi.org/10.1214/15-AOAS859 in the Annals of Applied Statistics (http://www.imstat.org/aoas/) by the Institute of Mathematical Statistics (http://www.imstat.org

Merging Data Sources to Predict Remaining Useful Life – An Automated Method to Identify Prognostic Parameters

The ultimate goal of most prognostic systems is accurate prediction of the remaining useful life (RUL) of individual systems or components based on their use and performance. This class of prognostic algorithms is termed Degradation-Based, or Type III Prognostics. As equipment degrades, measured parameters of the system tend to change; these sensed measurements, or appropriate transformations thereof, may be used to characterize degradation. Traditionally, individual-based prognostic methods use a measure of degradation to make RUL estimates. Degradation measures may include sensed measurements, such as temperature or vibration level, or inferred measurements, such as model residuals or physics-based model predictions. Often, it is beneficial to combine several measures of degradation into a single parameter. Selection of an appropriate parameter is key for making useful individual-based RUL estimates, but methods to aid in this selection are absent in the literature. This dissertation introduces a set of metrics which characterize the suitability of a prognostic parameter. Parameter features such as trendability, monotonicity, and prognosability can be used to compare candidate prognostic parameters to determine which is most useful for individual-based prognosis. Trendability indicates the degree to which the parameters of a population of systems have the same underlying shape. Monotonicity characterizes the underlying positive or negative trend of the parameter. Finally, prognosability gives a measure of the variance in the critical failure value of a population of systems. By quantifying these features for a given parameter, the metrics can be used with any traditional optimization technique, such as Genetic Algorithms, to identify the optimal parameter for a given system. An appropriate parameter may be used with a General Path Model (GPM) approach to make RUL estimates for specific systems or components. A dynamic Bayesian updating methodology is introduced to incorporate prior information in the GPM methodology. The proposed methods are illustrated with two applications: first, to the simulated turbofan engine data provided in the 2008 Prognostics and Health Management Conference Prognostics Challenge and, second, to data collected in a laboratory milling equipment wear experiment. The automated system was shown to identify appropriate parameters in both situations and facilitate Type III prognostic model development

Condition-based maintenance for a system subject to multiple degradation processes with stochastic arrival intensity

In this work, a system subject to different deterioration processes is analysed. The arrival of the degradation processes to the system is modelled using a shot-noise Cox process. The degradation processes grow according to an homogeneous gamma process. The system fails when a degradation process exceeds a failure threshold. The combined process of initiation and growth of the degradation processes is modelled and the system reliability is obtained. Heterogeneities are also integrated in the model assuming that the inverse of the scale parameter follows a uniform distribution. A maintenance strategy is implemented in this system and the state of the system is checked in inspection times. If the system is working at inspection time, a preventive replacement is performed if the deterioration level of a degradation process exceeds a certain threshold. A corrective replacement is performed if the system is down at inspection time. Under this maintenance strategy, the expected cost rate is obtained. Sensitivity analysis on the main parameters of the gamma process is performed.Comment: 30 pages, 10 figure

Maintenance Optimization and Inspection Planning of Wind Energy Assets: Models, Methods and Strategies

Designing cost-effective inspection and maintenance programmes for wind energy farms is a complex task involving a high degree of uncertainty due to diversity of assets and their corresponding damage mechanisms and failure modes, weather-dependent transport conditions, unpredictable spare parts demand, insufficient space or poor accessibility for maintenance and repair, limited availability of resources in terms of equipment and skilled manpower, etc. In recent years, maintenance optimization has attracted the attention of many researchers and practitioners from various sectors of the wind energy industry, including manufacturers, component suppliers, maintenance contractors and others. In this paper, we propose a conceptual classification framework for the available literature on maintenance policy optimization and inspection planning of wind energy systems and structures (turbines, foundations, power cables and electrical substations). The developed framework addresses a wide range of theoretical and practical issues, including the models, methods, and the strategies employed to optimise maintenance decisions and inspection procedures in wind farms. The literature published to date on the subject of this article is critically reviewed and several research gaps are identified. Moreover, the available studies are systematically classified using different criteria and some research directions of potential interest to operational researchers are highlighted

2nd International Workshop on Physics-Based Modelling of Material Properties and Experimental Observations with special focus on Fracture and Damage Mechanics: Book of Abstracts

This report covers the book of abstracts of the 2nd International Workshop on Physics Based Modelling of Material Properties and Experimental Observations, with special focus on Fracture and Damage Mechanics. The workshop is organized in the context of European Commission’s Enlargement and Integration Action, by the Joint Research Centre in collaboration with the TOBB University of Economics and Technology (TOBB ETU) on 15th-17th May 2013 in Antalya, Turkey. The abstracts of the keynote lectures and all the technical presentations are included in the book. This workshop will give an overview of different physics-based models for fracture and degradation of metallic materials and how they can be used for improved understanding and more reliable predictions. Models of interest include cohesive zones to simulate fracture processes, ductile-brittle transition for ferritic steels, ductile fracture mechanisms such as void growth or localized shear, fatigue crack initiation and short crack growth, environmental assisted cracking. Experimental studies that support such models and case studies that illustrate their use are also within the scope. The workshop is also an opportunity for scientists and engineers from EU Member States and target countries to discuss research activities that could be a basis for future collaborations.JRC.F.4-Nuclear Reactor Integrity Assessment and Knowledge Managemen

A model-based hybrid approach for circuit breaker prognostics encompassing dynamic reliability and uncertainty

Prognostics predictions estimate the remaining useful life of assets. This information enables the implementation of condition-based maintenance strategies by scheduling intervention when failure is imminent. Circuit breakers are key assets for the correct operation of the power network, fulfilling both a protection and a network reconfiguration role. Certain breakers will perform switching on a deterministic schedule, while operating stochastically in response to network faults. Both types of operation increase wear on the main contact, with high fault currents leading to more rapid ageing. This paper presents a hybrid approach for prognostics of circuit breakers, which integrates deterministic and stochastic operation through Piecewise Deterministic Markov Processes. The main contributions of this paper are (i) the integration of hybrid prognostics models with dynamic reliability concepts for a more accurate remaining useful life forecasting and (ii) the uncertain failure threshold modelling to integrate and propagate uncertain failure evaluation levels in the prognostics estimation process. Results show the effect of dynamic operation conditions on prognostics predictions and confirm the potential for its use within a condition-based maintenance strategy

Critical Infrastructures: Enhancing Preparedness & Resilience for the Security of Citizens and Services Supply Continuity: Proceedings of the 52nd ESReDA Seminar Hosted by the Lithuanian Energy Institute & Vytautas Magnus University

Critical Infrastructures Preparedness and Resilience is a major societal security issue in modern society. Critical Infrastructures (CIs) provide vital services to modern societies. Some CIs’ disruptions may endanger the security of the citizen, the safety of the strategic assets and even the governance continuity. The European Safety, Reliability and Data Association (ESReDA) as one of the most active EU networks in the field has initiated a project group on the “Critical Infrastructure/Modelling, Simulation and Analysis – Data”. The main focus of the project group is to report on the state of progress in MS&A of the CIs preparedness & resilience with a specific focus on the corresponding data availability and relevance. In order to report on the most recent developments in the field of the CIs preparedness & resilience MS&A and the availability of the relevant data, ESReDA held its 52nd Seminar on the following thematic: “Critical Infrastructures: Enhancing Preparedness & Resilience for the security of citizens and services supply continuity”. The 52nd ESReDA Seminar was a very successful event, which attracted about 50 participants from industry, authorities, operators, research centres, academia and consultancy companies.JRC.G.10-Knowledge for Nuclear Security and Safet

Bayesian Network Approach to Assessing System Reliability for Improving System Design and Optimizing System Maintenance

abstract: A quantitative analysis of a system that has a complex reliability structure always involves considerable challenges. This dissertation mainly addresses uncertainty in- herent in complicated reliability structures that may cause unexpected and undesired results. The reliability structure uncertainty cannot be handled by the traditional relia- bility analysis tools such as Fault Tree and Reliability Block Diagram due to their deterministic Boolean logic. Therefore, I employ Bayesian network that provides a flexible modeling method for building a multivariate distribution. By representing a system reliability structure as a joint distribution, the uncertainty and correlations existing between system’s elements can effectively be modeled in a probabilistic man- ner. This dissertation focuses on analyzing system reliability for the entire system life cycle, particularly, production stage and early design stages. In production stage, the research investigates a system that is continuously mon- itored by on-board sensors. With modeling the complex reliability structure by Bayesian network integrated with various stochastic processes, I propose several methodologies that evaluate system reliability on real-time basis and optimize main- tenance schedules. In early design stages, the research aims to predict system reliability based on the current system design and to improve the design if necessary. The three main challenges in this research are: 1) the lack of field failure data, 2) the complex reliability structure and 3) how to effectively improve the design. To tackle the difficulties, I present several modeling approaches using Bayesian inference and nonparametric Bayesian network where the system is explicitly analyzed through the sensitivity analysis. In addition, this modeling approach is enhanced by incorporating a temporal dimension. However, the nonparametric Bayesian network approach generally accompanies with high computational efforts, especially, when a complex and large system is modeled. To alleviate this computational burden, I also suggest to building a surrogate model with quantile regression. In summary, this dissertation studies and explores the use of Bayesian network in analyzing complex systems. All proposed methodologies are demonstrated by case studies.Dissertation/ThesisDoctoral Dissertation Industrial Engineering 201

Reliability and Condition-Based Maintenance Analysis of Deteriorating Systems Subject to Generalized Mixed Shock Model

For successful commercialization of evolving devices (e.g., micro-electro-mechanical systems, and biomedical devices), there must be new research focusing on reliability models and analysis tools that can assist manufacturing and maintenance of these devices. These advanced systems may experience multiple failure processes that compete against each other. Two major failure processes are identified to be deteriorating or degradation processes (e.g., wear, fatigue, erosion, corrosion) and random shocks. When these failure processes are dependent, it is a challenging problem to predict reliability of complex systems. This research aims to develop reliability models by exploring new aspects of dependency between competing risks of degradation-based and shock-based failure considering a generalized mixed shock model, and to develop new and effective condition-based maintenance policies based on the developed reliability models. In this research, different aspects of dependency are explored to accurately estimate the reliability of complex systems. When the degradation rate is accelerated as a result of withstanding a particular shock pattern, we develop reliability models with a changing degradation rate for four different shock patterns. When the hard failure threshold reduces due to changes in degradation, we investigate reliability models considering the dependence of the hard failure threshold on the degradation level for two different scenarios. More generally, when the degradation rate and the hard failure threshold can simultaneously transition multiple times, we propose a rich reliability model for a new generalized mixed shock model that is a combination of extreme shock model, δ-shock model and run shock model. This general assumption reflects complex behaviors associated with modern systems and structures that experience multiple sources of external shocks. Based on the developed reliability models, we introduce new condition-based maintenance strategies by including various maintenance actions (e.g., corrective replacement, preventive replacement, and imperfect repair) to minimize the expected long-run average maintenance cost rate. The decisions for maintenance actions are made based on the health condition of systems that can be observed through periodic inspection. The reliability and maintenance models developed in this research can provide timely and effective tools for decision-makers in manufacturing to economically optimize operational decisions for improving reliability, quality and productivity.Industrial Engineering, Department o