Framework for a space shuttle main engine health monitoring system

A framework developed for a health management system (HMS) which is directed at improving the safety of operation of the Space Shuttle Main Engine (SSME) is summarized. An emphasis was placed on near term technology through requirements to use existing SSME instrumentation and to demonstrate the HMS during SSME ground tests within five years. The HMS framework was developed through an analysis of SSME failure modes, fault detection algorithms, sensor technologies, and hardware architectures. A key feature of the HMS framework design is that a clear path from the ground test system to a flight HMS was maintained. Fault detection techniques based on time series, nonlinear regression, and clustering algorithms were developed and demonstrated on data from SSME ground test failures. The fault detection algorithms exhibited 100 percent detection of faults, had an extremely low false alarm rate, and were robust to sensor loss. These algorithms were incorporated into a hierarchical decision making strategy for overall assessment of SSME health. A preliminary design for a hardware architecture capable of supporting real time operation of the HMS functions was developed. Utilizing modular, commercial off-the-shelf components produced a reliable low cost design with the flexibility to incorporate advances in algorithm and sensor technology as they become available

Estimation of fuel cell operating time for prédictive maintenance strategies

International audienceOne of the limiting factors for the spreading of the fuel cell technology is the durability and researches to extend their lifetime are being done world-widely. We present here a pattern recognition approach aiming to estimate fuel cell operating time based on electrochemical impedance spectroscopy measurements. It consists in first extracting features from the impedance spectrum. For that purpose, two approaches have been investigated. In the first one, particular points of the spectrum are empirically extracted as features. In the second approach, a parametric modelling is performed to extract features from both the real and the imaginary parts of the impedance spectrum. In particular, a latent regression model is used to automatically split the spectrum into several segments that are approximated by polynomials. The number of segments is adjusted taking account the a priori knowledge about the physical behaviour of fuel cell components. Then, a linear regression model using different subsets of extracted features is employed for the estimation of fuel cell operating time. The performances of the proposed approach are evaluated on experimental data set to show its feasibility. Being able to estimate the fuel cell operating time, and consequently its remaining duration life, these results could lead to interesting perspectives for predictive maintenance policy of fuel cells

Machine learning and data-driven fault detection for ship systems operations

Well maintained vessels exhibit high reliability, safety and energy efficiency. Even though machinery failures are inevitable, their occurrence can be foreseen when predictive maintenance schemes are implemented. Predictive maintenance may be optimally applied through condition, performance, and process monitoring. Most importantly, it can include the detection of developing faults, which affect the performance of ship systems and hinder energy-efficient operations of ships. Under this viewpoint, this paper proposes a new data-driven fault detection methodology in a novel application for shipboard systems, by exploring the "learning potential" of recorded voyage data. The proposed methodology, combines the benefits of Expected Behaviour (EB) models, by selecting the optimal regression model, with the Exponentially Weighted Moving Average (EWMA) for fault detection, in novel ship applications. It is seen that a multiple polynomial ridge regression model, with testing R2 score of nearly 0.96 and can accurately detect certain developing faults manifesting in both the Main Engine (ME) cylinder Exhaust Gas (EG) temperature and the ME scavenging air pressure. The early detection of developing faults can be used to supplement the daily monitoring of ship operations and enable the planning of pre-emptive rectifying actions by reducing sub-optimal machinery conditions

Meta-heuristic algorithms in car engine design: a literature survey

Meta-heuristic algorithms are often inspired by natural phenomena, including the evolution of species in Darwinian natural selection theory, ant behaviors in biology, flock behaviors of some birds, and annealing in metallurgy. Due to their great potential in solving difficult optimization problems, meta-heuristic algorithms have found their way into automobile engine design. There are different optimization problems arising in different areas of car engine management including calibration, control system, fault diagnosis, and modeling. In this paper we review the state-of-the-art applications of different meta-heuristic algorithms in engine management systems. The review covers a wide range of research, including the application of meta-heuristic algorithms in engine calibration, optimizing engine control systems, engine fault diagnosis, and optimizing different parts of engines and modeling. The meta-heuristic algorithms reviewed in this paper include evolutionary algorithms, evolution strategy, evolutionary programming, genetic programming, differential evolution, estimation of distribution algorithm, ant colony optimization, particle swarm optimization, memetic algorithms, and artificial immune system

Data-Driven and Hybrid Methods for Naval Applications

The goal of this PhD thesis is to study, design and develop data analysis methods for naval applications. Data analysis is improving our ways to understand complex phenomena by profitably taking advantage of the information laying behind a collection of data. In fact, by adopting algorithms coming from the world of statistics and machine learning it is possible to extract valuable information, without requiring specific domain knowledge of the system generating the data. The application of such methods to marine contexts opens new research scenarios, since typical naval problems can now be solved with higher accuracy rates with respect to more classical techniques, based on the physical equations governing the naval system. During this study, some major naval problems have been addressed adopting state-of-the-art and novel data analysis techniques: condition-based maintenance, consisting in assets monitoring, maintenance planning, and real-time anomaly detection; energy and consumption monitoring, in order to reduce vessel consumption and gas emissions; system safety for maneuvering control and collision avoidance; components design, in order to detect possible defects at design stage. A review of the state-of-the-art of data analysis and machine learning techniques together with the preliminary results of the application of such methods to the aforementioned problems show a growing interest in these research topics and that effective data-driven solutions can be applied to the naval context. Moreover, for some applications, data-driven models have been used in conjunction with domain-dependent methods, modelling physical phenomena, in order to exploit both mechanistic knowledge of the system and available measurements. These hybrid methods are proved to provide more accurate and interpretable results with respect to both the pure physical or data-driven approaches taken singularly, thus showing that in the naval context it is possible to offer new valuable methodologies by either providing novel statistical methods or improving the state-of-the-art ones

Performance-based health monitoring, diagnostics and prognostics for condition-based maintenance of gas turbines: A review

With the privatization and intense competition that characterize the volatile energy sector, the gas turbine industry currently faces new challenges of increasing operational flexibility, reducing operating costs, improving reliability and availability while mitigating the environmental impact. In this complex, changing sector, the gas turbine community could address a set of these challenges by further development of high fidelity, more accurate and computationally efficient engine health assessment, diagnostic and prognostic systems. Recent studies have shown that engine gas-path performance monitoring still remains the cornerstone for making informed decisions in operation and maintenance of gas turbines. This paper offers a systematic review of recently developed engine performance monitoring, diagnostic and prognostic techniques. The inception of performance monitoring and its evolution over time, techniques used to establish a high-quality dataset using engine model performance adaptation, and effects of computationally intelligent techniques on promoting the implementation of engine fault diagnosis are reviewed. Moreover, recent developments in prognostics techniques designed to enhance the maintenance decision-making scheme and main causes of gas turbine performance deterioration are discussed to facilitate the fault identification module. The article aims to organize, evaluate and identify patterns and trends in the literature as well as recognize research gaps and recommend new research areas in the field of gas turbine performance-based monitoring. The presented insightful concepts provide experts, students or novice researchers and decision-makers working in the area of gas turbine engines with the state of the art for performance-based condition monitoring

Implementation of a Bayesian linear regression framework for nuclear prognostics

Steam turbines are an important asset of nuclear power plants (NPPs), and are required to operate reliably and efficiently. Unplanned outages have a significant impact on the ability of the plant to generate electricity. Therefore, predictive and proactive maintenance which can avoid unplanned outages has the potential to reduce operating costs while increasing the reliability and availability of the plant. A case study from the data of an operational steam turbine of a NPP in the UK was used for the implementation of a Bayesian Linear Regression (BLR) framework. An appropriate model for the deterioration under study is selected. The BLR framework was applied as a prognostic technique in order to calculate the remaining useful life (RUL). Results show that the accuracy of the technique varies due to the nature of the data that is utilised to estimate the model parameters

Sensing for aerospace combustor health monitoring

Purpose This paper proposes new methods of fault detection for fuel systems in order to improve system availability. Novel fault systems are required for environmentally friendly lean burn combustion, but can carry high risk failure modes particularly through their control valves. The purpose of the developed technology is the rapid detection of these failure modes, such as valve sticking or impending sticking, and therefore to reduce this risk. However, sensing valve state is challenging due to hot environmental temperatures, which results in a low reliability for conventional position sensing. Design/methodology/approach Starting with the business needs elicited from stakeholders, a quality functional deployment process is performed to derive sensing system requirements. The process acknowledges the difference between test-bed and in-service aerospace needs through weightings on requirements and maps these customer requirements to systems performance metrics. The design of the system must therefore optimise the sensor suite, on- and off-board signal processing and acquisition strategy. Findings Against this systems engineering process, two sensing strategies are outlined which illustrate the span of solutions, from conventional gas path sensing with advanced signal processing to novel non-invasive sensing concepts. While conventional sensing may be feasible within a test cell, the constraints of aerospace in-service operation may necessitate more novel alternatives. Acoustic emission (detecting very high frequency surface vibration waves) sensing technology is evaluated to provide a non-invasive, remote and high temperature tolerant solution. Through this comparison, the considerations for the end-to-end system design are highlighted to be critical to sensor deployment success in-service. Practical implications The paper provides insight into different means of addressing the important problem of monitoring faults in combustor systems in gas turbines. By casting of the complex design problem within a systems engineering framework, the outline of a toolset for solution evaluation is provided. Originality/value The paper provides three areas of significant contributions: a diversity of methods to diagnosing fuel system malfunctions by measuring changes fuel flow distributions, through novel means, and the combustor exit temperature profiles (cause and effect); the use of analytical methods to support the selection (types and quantities) and placement of sensors to ensure adequate state awareness while minimising their impact on the engine system cost and weight; and an end-to-end data processing approach to provide optimised information for the engine maintainers allowing informed decision-making

Multi-Modular Integral Pressurized Water Reactor Control and Operational Reconfiguration for a Flow Control Loop

This dissertation focused on the IRIS design since this will likely be one of the designs of choice for future deployment in the U.S and developing countries. With a net 335 MWe output IRIS novel design falls in the “medium” size category and it is a potential candidate for the so called modular reactors, which may be appropriate for base load electricity generation, especially in regions with smaller electricity grids, but especially well suited for more specialized non-electrical energy applications such as district heating and process steam for desalination. The first objective of this dissertation is to evaluate and quantify the performance of a Nuclear Power Plant (NPP) comprised of two IRIS reactor modules operating simultaneously with a common steam header, which in turn is connected to a single turbine, resulting in a steam-mixing control problem with respect to “load-following” scenarios, such as varying load during the day or reduced consumption during the weekend. To solve this problem a single-module IRIS SIMULINK model previously developed by another researcher is modified to include a second module and was used to quantify the responses from both modules. In order to develop research related to instrumentation and control, and equipment and sensor monitoring, the second objective is to build a two-tank multivariate loop in the Nuclear Engineering Department at the University of Tennessee. This loop provides the framework necessary to investigate and test control strategies and fault detection in sensors, equipment and actuators. The third objective is to experimentally develop and demonstrate a fault-tolerant control strategy using this loop. Using six correlated variables in a single-tank configuration, five inferential models and one Auto-Associative Kernel Regression (AAKR) model were developed to detect faults in process sensors. Once detected the faulty measurements were successfully substituted with prediction values, which would provide the necessary flexibility and time to find the source of discrepancy and resolve it, such as in an operating power plant. Finally, using the same empirical models, an actuator failure was simulated and once detected the control was automatically transferred and reconfigured from one tank to another, providing survivability to the system

PEMFC performance improvement through oxygen starvation prevention, modeling, and diagnosis of hydrogen leakage

Catalyst degradation results in emerging pinholes in Proton Exchange Membrane Fuel Cells (PEMFCs) and subsequently hydrogen leakage. Oxygen starvation resulting from hydrogen leaks is one of the primary life-limiting factors in PEMFCs. Voltage reduces as a result of oxygen starvation, and the cell performance deteriorates. Starved PEMFCs also work as a hydrogen pump, increasing the amount of hydrogen on the cathode side, resulting in hydrogen emissions. Therefore, it is important to delay the occurrence of oxygen starvation within the Membrane Electrode Assembly (MEA) while simultaneously be able to diagnose the hydrogen crossover through the pinholes. In this work, first, we focus on catalyst configuration as a novel method to prevent oxygen starvation and catalyst degradation. It is hypothesized that the redistribution of the platinum catalyst can increase the maximum current density and prevent oxygen starvation and catalyst degradation. Therefore, a multi-objective optimization problem is defined to maximize fuel cell efficiency and to prevent oxygen starvation in the PEMFC. Results indicate that the maximum current density rises about eight percent, while the maximum PEMFC power density increases by twelve percent. In the next step, a previously developed pseudo two-dimensional model is used to simulate fuel cell behavior in the normal and the starvation mode. This model is developed further to capture the effect of the hydrogen pumping phenomenon and to measure the amount of hydrogen in the outlet of the cathode channel. The results obtained from the model are compared with the experimental data, and validation shows that the proposed model is fast and precise. Next, Machine Learning (ML) estimators are used to first detect whether there is a hydrogen crossover in the fuel cell and second to capture the amount of hydrogen cross over. K Nearest Neighbour (KNN) and Artificial Neural Network (ANN) estimators are chosen for leakage detection and classification. Eventually, a pair of ANN classifier-regressor is chosen to first isolate leaky PEMFCs and then quantify the amount of leakage. The classifier and regressor are both trained on the datasets that are generated by the pseudo two-dimensional model. Different performance indexes are evaluated to assure that the model is not underfitting/overfitting. This ML diagnosis algorithm can be employed as an onboard diagnosis system that can be used to detect and possibly prevent cell reversal failures