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

Production Optimization Indexed to the Market Demand Through Neural Networks

Connectivity, mobility and real-time data analytics are the prerequisites for a new model of intelligent production management that facilitates communication between machines, people and processes and uses technology as the main driver. Many works in the literature treat maintenance and production management in separate approaches, but there is a link between these areas, with maintenance and its actions aimed at ensuring the smooth operation of equipment to avoid unnecessary downtime in production. With the advent of technology, companies are rushing to solve their problems by resorting to technologies in order to fit into the most advanced technological concepts, such as industries 4.0 and 5.0, which are based on the principle of process automation. This approach brings together database technologies, making it possible to monitor the operation of equipment and have the opportunity to study patterns of data behavior that can alert us to possible failures. The present thesis intends to forecast the pulp production indexed to the stock market value.The forecast will be made by means of the pulp production variables of the presses and the stock exchange variables supported by artificial intelligence (AI) technologies, aiming to achieve an effective planning. To support the decision of efficient production management, in this thesis algorithms were developed and validated with from five pulp presses, as well as data from other sources, such as steel production and stock exchange, which were relevant to validate the robustness of the model. This thesis demonstrated the importance of data processing methods and that they have great relevance in the model input since they facilitate the process of training and testing the models. The chosen technologies demonstrated good efficiency and versatility in performing the prediction of the values of the variables of the equipment, also demonstrating robustness and optimization in computational processing. The thesis also presents proposals for future developments, namely in further exploration of these technologies, so that there are market variables that can calibrate production through forecasts supported on these same variables.Conectividade, mobilidade e análise de dados em tempo real são pré-requisitos para um novo modelo de gestão inteligente da produção que facilita a comunicação entre máquinas, pessoas e processos, e usa a tecnologia como motor principal. Muitos trabalhos na literatura tratam a manutenção e a gestão da produção em abordagens separadas, mas existe uma correlação entre estas áreas, sendo que a manutenção e as suas políticas têm como premissa garantir o bom funcionamento dos equipamentos de modo a evitar paragens desnecessárias na linha de produção. Com o advento da tecnologia há uma corrida das empresas para solucionar os seus problemas recorrendo às tecnologias, visando a sua inserção nos conceitos tecnológicos, mais avançados, tais como as indústrias 4.0 e 5.0, as quais têm como princípio a automatização dos processos. Esta abordagem junta as tecnologias de sistema de informação, sendo possível fazer o acompanhamento do funcionamento dos equipamentos e ter a possibilidade de realizar o estudo de padrões de comportamento dos dados que nos possam alertar para possíveis falhas. A presente tese pretende prever a produção da pasta de papel indexada às bolsas de valores. A previsão será feita por via das variáveis da produção da pasta de papel das prensas e das variáveis da bolsa de valores suportadas em tecnologias de artificial intelligence (IA), tendo como objectivo conseguir um planeamento eficaz. Para suportar a decisão de uma gestão da produção eficiente, na presente tese foram desenvolvidos algoritmos, validados em dados de cinco prensas de pasta de papel, bem como dados de outras fontes, tais como, de Produção de Aço e de Bolsas de Valores, os quais se mostraram relevantes para a validação da robustez dos modelos. A presente tese demonstrou a importância dos métodos de tratamento de dados e que os mesmos têm uma grande relevância na entrada do modelo, visto que facilita o processo de treino e testes dos modelos. As tecnologias escolhidas demonstraram uma boa eficiência e versatilidade na realização da previsão dos valores das variáveis dos equipamentos, demonstrando ainda robustez e otimização no processamento computacional. A tese apresenta ainda propostas para futuros desenvolvimentos, designadamente na exploração mais aprofundada destas tecnologias, de modo a que haja variáveis de mercado que possam calibrar a produção através de previsões suportadas nestas mesmas variáveis

Review of Health Prognostics and Condition Monitoring of Electronic Components

To meet the specifications of low cost, highly reliable electronic devices, fault diagnosis techniques play an essential role. It is vital to find flaws at an early stage in design, components, material, or manufacturing during the initial phase. This review paper attempts to summarize past development and recent advances in the areas about green manufacturing, maintenance, remaining useful life (RUL) prediction, and like. The current state of the art in reliability research for electronic components, mainly includes failure mechanisms, condition monitoring, and residual lifetime evaluation is explored. A critical analysis of reliability studies to identify their relative merits and usefulness of the outcome of these studies' vis-a-vis green manufacturing is presented. The wide array of statistical, empirical, and intelligent tools and techniques used in the literature are then identified and mapped. Finally, the findings are summarized, and the central research gap is highlighted

NOVELTY DETECTION FOR PREDICTIVE MAINTENANCE

Since the advent of Industry 4. 0 significant research has been conducted to apply machine learning to the vast array of Internet of Things (IoT) data produced by Industrial Machines. One such topic is to Predictive Maintenance. Unlike some other machine learning domains such as NLP and computer vision, Predictive Maintenance is a relatively new area of focus. Most of the published work demonstrates the effectiveness of supervised classification for predictive maintenance. Some of the challenges highlighted in the literature are the cost and difficulty of obtaining labelled samples for training. Novelty detection is a branch of machine learning that after being trained on normal operations detects if new data comes from the same process or is different, eliminating the requirement to label data points. This thesis applies novelty detection to both a public data set and one that was specifically collected to demonstrate a its application to predictive maintenance. The Local Optimization Factor showed better performance than a One-Class SVM on the public data. It was then applied to data from a 3-D printer and was able to detect faults it had not been trained on showing a slight lift from a random classifier

Integrated performance prediction and quality control in manufacturing systems

textPredicting the condition of a degrading dynamic system is critical for implementing successful control and designing the optimal operation and maintenance strategies throughout the lifetime of the system. In many situations, especially in manufacturing, systems experience multiple degradation cycles, failures, and maintenance events throughout their lifetimes. In such cases, historical records of sensor readings observed during the lifecycle of a machine can yield vital information about degradation patterns of the monitored machine, which can be used to formulate dynamic models for predicting its future performance. Besides the ability to predict equipment failures, another major component of cost effective and high-throughput manufacturing is tight control of product quality. Quality control is assured by taking periodic measurements of the products at various stages of production. Nevertheless, quality measurements of the product require time and are often executed on costly measurement equipment, which increases the cost of manufacturing and slows down production. One possible way to remedy this situation is to utilize the inherent link between the manufacturing equipment condition, mirrored in the readings of sensors mounted on that machine, and the quality of products coming out of it. The concept of Virtual Metrology (VM) addresses the quality control problem by using data-driven models that relate the product quality to the equipment sensors, enabling continuous estimation of the quality characteristics of the product, even when physical measurements of product quality are not available. VM can thus bring significant production benefits, including improved process control, reduced quality losses and higher productivity. In this dissertation, new methods are formulated that will combine long-term performance prediction of sensory signatures from a degrading manufacturing machine with VM quality estimation, which enables integration of predictive condition monitoring (prediction of sensory signatures) with predictive manufacturing process control (predictive VM model). The recently developed algorithm for prediction of sensory signatures is capable of predicting the system condition by comparing the similarity of the most recent performance signatures with the known degradation patterns available in the historical records. The method accomplishes the prediction of non-Gaussian and non-stationary time-series of relevant performance signatures with analytical tractability, which enables calculations of predicted signature distributions with significantly greater speeds than what can be found in literature. VM quality estimation is implemented using the recently introduced growing structure multiple model system paradigm (GSMMS), based on the use of local linear dynamic models. The concept of local models enables representation of complex, non-linear dependencies with non-Gaussian and non-stationary noise characteristics, using a locally tractable model representation. Localized modeling enables a VM that can detect situations when the VM model is not adequate and needs to be improved, which is one of the main challenges in VM. Finally, uncertainty propagation with Monte Carlo simulation is pursued in order to propagate the predicted distributions of equipment signatures through the VM model to enable prediction of distributions of the quality variables using the readily available sensor readings streaming from the monitored manufacturing machine. The newly developed methods are applied to long-term production data coming from an industrial plasma-enhanced chemical vapor deposition (PECVD) tool operating in a major semiconductor manufacturing fab.Mechanical Engineerin

An investigation into the prognosis of electromagnetic relays.

Electrical contacts provide a well-proven solution to switching various loads in a wide variety of applications, such as power distribution, control applications, automotive and telecommunications. However, electrical contacts are known for limited reliability due to degradation effects upon the switching contacts due to arcing and fretting. Essentially, the life of the device may be determined by the limited life of the contacts. Failure to trip, spurious tripping and contact welding can, in critical applications such as control systems for avionics and nuclear power application, cause significant costs due to downtime, as well as safety implications. Prognostics provides a way to assess the remaining useful life (RUL) of a component based on its current state of health and its anticipated future usage and operating conditions. In this thesis, the effects of contact wear on a set of electromagnetic relays used in an avionic power controller is examined, and how contact resistance combined with a prognostic approach, can be used to ascertain the RUL of the device. Two methodologies are presented, firstly a Physics based Model (PbM) of the degradation using the predicted material loss due to arc damage. Secondly a computationally efficient technique using posterior degradation data to form a state space model in real time via a Sliding Window Recursive Least Squares (SWRLS) algorithm. Health monitoring using the presented techniques can provide knowledge of impending failure in high reliability applications where the risks associated with loss-of-functionality are too high to endure. The future states of the systems has been estimated based on a Particle and Kalman-filter projection of the models via a Bayesian framework. Performance of the prognostication health management algorithm during the contacts life has been quantified using performance evaluation metrics. Model predictions have been correlated with experimental data. Prognostic metrics including Prognostic Horizon (PH), alpha-Lamda (α-λ), and Relative Accuracy have been used to assess the performance of the damage proxies and a comparison of the two models made

Accommodating maintenance in prognostics

Error on title page - year of award is 2021Steam turbines are an important asset of nuclear power plants, and are required to operate reliably and efficiently. Unplanned outages have a significant impact on the ability of the plant to generate electricity. Therefore, condition-based maintenance (CBM) can be used for predictive and proactive maintenance to avoid unplanned outages while reducing operating costs and increasing the reliability and availability of the plant. In CBM, the information gathered can be interpreted for prognostics (the prediction of failure time or remaining useful life (RUL)). The aim of this project was to address two areas of challenges in prognostics, the selection of predictive technique and accommodation of post-maintenance effects, to improve the efficacy of prognostics. The selection of an appropriate predictive algorithm is a key activity for an effective development of prognostics. In this research, a formal approach for the evaluation and selection of predictive techniques is developed to facilitate a methodic selection process of predictive techniques by engineering experts. This approach is then implemented for a case study provided by the engineering experts. Therefore, as a result of formal evaluation, a probabilistic technique the Bayesian Linear Regression (BLR) and a non-probabilistic technique the Support Vector Regression (SVR) were selected for prognostics implementation. In this project, the knowledge of prognostics implementation is extended by including post maintenance affects into prognostics. Maintenance aims to restore a machine into a state where it is safe and reliable to operate while recovering the health of the machine. However, such activities result in introduction of uncertainties that are associated with predictions due to deviations in degradation model. Thus, affecting accuracy and efficacy of predictions. Therefore, such vulnerabilities must be addressed by incorporating the information from maintenance events for accurate and reliable predictions. This thesis presents two frameworks which are adapted for probabilistic and non-probabilistic prognostic techniques to accommodate maintenance. Two case studies: a real-world case study from a nuclear power plant in the UK and a synthetic case study which was generated based on the characteristics of a real-world case study are used for the implementation and validation of the frameworks. The results of the implementation hold a promise for predicting remaining useful life while accommodating maintenance repairs. Therefore, ensuring increased asset availability with higher reliability, maintenance cost effectiveness and operational safety.Steam turbines are an important asset of nuclear power plants, and are required to operate reliably and efficiently. Unplanned outages have a significant impact on the ability of the plant to generate electricity. Therefore, condition-based maintenance (CBM) can be used for predictive and proactive maintenance to avoid unplanned outages while reducing operating costs and increasing the reliability and availability of the plant. In CBM, the information gathered can be interpreted for prognostics (the prediction of failure time or remaining useful life (RUL)). The aim of this project was to address two areas of challenges in prognostics, the selection of predictive technique and accommodation of post-maintenance effects, to improve the efficacy of prognostics. The selection of an appropriate predictive algorithm is a key activity for an effective development of prognostics. In this research, a formal approach for the evaluation and selection of predictive techniques is developed to facilitate a methodic selection process of predictive techniques by engineering experts. This approach is then implemented for a case study provided by the engineering experts. Therefore, as a result of formal evaluation, a probabilistic technique the Bayesian Linear Regression (BLR) and a non-probabilistic technique the Support Vector Regression (SVR) were selected for prognostics implementation. In this project, the knowledge of prognostics implementation is extended by including post maintenance affects into prognostics. Maintenance aims to restore a machine into a state where it is safe and reliable to operate while recovering the health of the machine. However, such activities result in introduction of uncertainties that are associated with predictions due to deviations in degradation model. Thus, affecting accuracy and efficacy of predictions. Therefore, such vulnerabilities must be addressed by incorporating the information from maintenance events for accurate and reliable predictions. This thesis presents two frameworks which are adapted for probabilistic and non-probabilistic prognostic techniques to accommodate maintenance. Two case studies: a real-world case study from a nuclear power plant in the UK and a synthetic case study which was generated based on the characteristics of a real-world case study are used for the implementation and validation of the frameworks. The results of the implementation hold a promise for predicting remaining useful life while accommodating maintenance repairs. Therefore, ensuring increased asset availability with higher reliability, maintenance cost effectiveness and operational safety

Developing Hybrid Machine Learning Models to Assign Health Score to Railcar Fleets for Optimal Decision Making

A large amount of data is generated during the operation of a railcar fleet, which can easily lead to dimensional disaster and reduce the resiliency of the railcar network. To solve these issues and offer predictive maintenance, this research introduces a hybrid fault diagnosis expert system method that combines density-based spatial clustering of applications with noise (DBSCAN) and principal component analysis (PCA). Firstly, the DBSCAN method is used to cluster categorical data that are similar to one another within the same group. Secondly, PCA algorithm is applied to reduce the dimensionality of the data and eliminate redundancy in order to improve the accuracy of fault diagnosis. Finally, we explain the engineered features and evaluate the selected models by using the Gain Chart and Area Under Curve (AUC) metrics. We use the hybrid expert system model to enhance maintenance planning decisions by assigning a health score to the railcar system of the North American Railcar Owner (NARO). According to the experimental results, our expert model can detect 96.4% of failures within 50% of the sample. This suggests that our method is effective at diagnosing failures in railcars fleet.Comment: 21 pages, 7 figures, 3 table