Wind turbine condition monitoring : technical and commercial challenges.

Deployment of larger scale wind turbine systems, particularly offshore, requires more organized operation and maintenance strategies to ensure systems are safe, profitable and cost-effective. Among existing maintenance strategies, reliability centred maintenance is regarded as best for offshore wind turbines, delivering corrective and proactive (i.e. preventive and predictive) maintenance techniques enabling wind turbines to achieve high availability and low cost of energy. Reliability centred maintenance analysis may demonstrate that an accurate and reliable condition monitoring system is one method to increase availability and decrease the cost of energy from wind. In recent years, efforts have been made to develop efficient and cost-effective condition monitoring techniques for wind turbines. A number of commercial wind turbine monitoring systems are available in the market, most based on existing techniques from other rotating machine industries. Other wind turbine condition monitoring reviews have been published but have not addressed the technical and commercial challenges, in particular, reliability and value for money. The purpose of this paper is to fill this gap and present the wind industry with a detailed analysis of the current practical challenges with existing wind turbine condition monitoring technology

Applied Sensor Fault Detection, Identification and Data Reconstruction

Sensor fault detection and identification (SFD/I) has attracted considerable attention in military applications, especially when safety- or mission-critical issues are of paramount importance. Here, two readily implementable approaches for SFD/I are proposed through hierarchical clustering and self-organizing map neural networks. The proposed methodologies are capable of detecting sensor faults from a large group of sensors measuring different physical quantities and achieve SFD/I in a single stage. Furthermore, it is possible to reconstruct the measurements expected from the faulted sensor and thereby facilitate improved unit availability. The efficacy of the proposed approaches is demonstrated through the use of measurements from experimental trials on a gas turbine. Ultimately, the underlying principles are readily transferable to other complex industrial and military systems

Canonical variate dissimilarity analysis for process incipient fault detection

Early detection of incipient faults in industrial processes is increasingly becoming important, as these faults can slowly develop into serious abnormal events, an emergency situation, or even failure of critical equipment. Multivariate statistical process monitoring methods are currently established for abrupt fault detection. Among these, canonical variate analysis (CVA) was proven to be effective for dynamic process monitoring. However, the traditional CVA indices may not be sensitive enough for incipient faults. In this work, an extension of CVA, called the canonical variate dissimilarity analysis (CVDA), is proposed for process incipient fault detection in nonlinear dynamic processes under varying operating conditions. To handle non-Gaussian distributed data, kernel density estimation was used for computing detection limits. A CVA dissimilarity-based index has been demonstrated to outperform traditional CVA indices and other dissimilarity-based indices, namely DISSIM, RDTCSA, and GCCA, in terms of sensitivity when tested on slowly developing multiplicative and additive faults in a CSTR under closed-loop control and varying operating conditions

Bridge damage detection based on vibration data: past and new developments

Overtime, bridge condition declines due to a number of degradation processes such as creep, corrosion, and cyclic loading, among others. Traditionally, vibration-based damage detection techniques in bridges have focused on monitoring changes to modal parameters. These techniques can often suffer to their sensitivity to changes in environmental and operational conditions, mistaking them as structural damage. Recent research has seen the emergence of more advanced computational techniques that not only allow the assessment of noisier and more complex data but also allow research to veer away from monitoring changes in modal parameters alone. This paper presents a review of the current state-of-the-art developments in vibration-based damage detection in small to medium span bridges with particular focus on the utilization of advanced computational methods that avoid traditional damage detection pitfalls. A case study based on the S101 bridge is also presented to test the damage sensitivity to a chosen methodology.Peer ReviewedPostprint (published version

An investigation on automatic systems for fault diagnosis in chemical processes

Plant safety is the most important concern of chemical industries. Process faults can cause economic loses as well as human and environmental damages. Most of the operational faults are normally considered in the process design phase by applying methodologies such as Hazard and Operability Analysis (HAZOP). However, it should be expected that failures may occur in an operating plant. For this reason, it is of paramount importance that plant operators can promptly detect and diagnose such faults in order to take the appropriate corrective actions. In addition, preventive maintenance needs to be considered in order to increase plant safety. Fault diagnosis has been faced with both analytic and data-based models and using several techniques and algorithms. However, there is not yet a general fault diagnosis framework that joins detection and diagnosis of faults, either registered or non-registered in records. Even more, less efforts have been focused to automate and implement the reported approaches in real practice. According to this background, this thesis proposes a general framework for data-driven Fault Detection and Diagnosis (FDD), applicable and susceptible to be automated in any industrial scenario in order to hold the plant safety. Thus, the main requirement for constructing this system is the existence of historical process data. In this sense, promising methods imported from the Machine Learning field are introduced as fault diagnosis methods. The learning algorithms, used as diagnosis methods, have proved to be capable to diagnose not only the modeled faults, but also novel faults. Furthermore, Risk-Based Maintenance (RBM) techniques, widely used in petrochemical industry, are proposed to be applied as part of the preventive maintenance in all industry sectors. The proposed FDD system together with an appropriate preventive maintenance program would represent a potential plant safety program to be implemented. Thus, chapter one presents a general introduction to the thesis topic, as well as the motivation and scope. Then, chapter two reviews the state of the art of the related fields. Fault detection and diagnosis methods found in literature are reviewed. In this sense a taxonomy that joins both Artificial Intelligence (AI) and Process Systems Engineering (PSE) classifications is proposed. The fault diagnosis assessment with performance indices is also reviewed. Moreover, it is exposed the state of the art corresponding to Risk Analysis (RA) as a tool for taking corrective actions to faults and the Maintenance Management for the preventive actions. Finally, the benchmark case studies against which FDD research is commonly validated are examined in this chapter. The second part of the thesis, integrated by chapters three to six, addresses the methods applied during the research work. Chapter three deals with the data pre-processing, chapter four with the feature processing stage and chapter five with the diagnosis algorithms. On the other hand, chapter six introduces the Risk-Based Maintenance techniques for addressing the plant preventive maintenance. The third part includes chapter seven, which constitutes the core of the thesis. In this chapter the proposed general FD system is outlined, divided in three steps: diagnosis model construction, model validation and on-line application. This scheme includes a fault detection module and an Anomaly Detection (AD) methodology for the detection of novel faults. Furthermore, several approaches are derived from this general scheme for continuous and batch processes. The fourth part of the thesis presents the validation of the approaches. Specifically, chapter eight presents the validation of the proposed approaches in continuous processes and chapter nine the validation of batch process approaches. Chapter ten raises the AD methodology in real scaled batch processes. First, the methodology is applied to a lab heat exchanger and then it is applied to a Photo-Fenton pilot plant, which corroborates its potential and success in real practice. Finally, the fifth part, including chapter eleven, is dedicated to stress the final conclusions and the main contributions of the thesis. Also, the scientific production achieved during the research period is listed and prospects on further work are envisaged.La seguridad de planta es el problema más inquietante para las industrias químicas. Un fallo en planta puede causar pérdidas económicas y daños humanos y al medio ambiente. La mayoría de los fallos operacionales son previstos en la etapa de diseño de un proceso mediante la aplicación de técnicas de Análisis de Riesgos y de Operabilidad (HAZOP). Sin embargo, existe la probabilidad de que pueda originarse un fallo en una planta en operación. Por esta razón, es de suma importancia que una planta pueda detectar y diagnosticar fallos en el proceso y tomar las medidas correctoras adecuadas para mitigar los efectos del fallo y evitar lamentables consecuencias. Es entonces también importante el mantenimiento preventivo para aumentar la seguridad y prevenir la ocurrencia de fallos. La diagnosis de fallos ha sido abordada tanto con modelos analíticos como con modelos basados en datos y usando varios tipos de técnicas y algoritmos. Sin embargo, hasta ahora no existe la propuesta de un sistema general de seguridad en planta que combine detección y diagnosis de fallos ya sea registrados o no registrados anteriormente. Menos aún se han reportado metodologías que puedan ser automatizadas e implementadas en la práctica real. Con la finalidad de abordar el problema de la seguridad en plantas químicas, esta tesis propone un sistema general para la detección y diagnosis de fallos capaz de implementarse de forma automatizada en cualquier industria. El principal requerimiento para la construcción de este sistema es la existencia de datos históricos de planta sin previo filtrado. En este sentido, diferentes métodos basados en datos son aplicados como métodos de diagnosis de fallos, principalmente aquellos importados del campo de “Aprendizaje Automático”. Estas técnicas de aprendizaje han resultado ser capaces de detectar y diagnosticar no sólo los fallos modelados o “aprendidos”, sino también nuevos fallos no incluidos en los modelos de diagnosis. Aunado a esto, algunas técnicas de mantenimiento basadas en riesgo (RBM) que son ampliamente usadas en la industria petroquímica, son también propuestas para su aplicación en el resto de sectores industriales como parte del mantenimiento preventivo. En conclusión, se propone implementar en un futuro no lejano un programa general de seguridad de planta que incluya el sistema de detección y diagnosis de fallos propuesto junto con un adecuado programa de mantenimiento preventivo. Desglosando el contenido de la tesis, el capítulo uno presenta una introducción general al tema de esta tesis, así como también la motivación generada para su desarrollo y el alcance delimitado. El capítulo dos expone el estado del arte de las áreas relacionadas al tema de tesis. De esta forma, los métodos de detección y diagnosis de fallos encontrados en la literatura son examinados en este capítulo. Asimismo, se propone una taxonomía de los métodos de diagnosis que unifica las clasificaciones propuestas en el área de Inteligencia Artificial y de Ingeniería de procesos. En consecuencia, se examina también la evaluación del performance de los métodos de diagnosis en la literatura. Además, en este capítulo se revisa y reporta el estado del arte correspondiente al “Análisis de Riesgos” y a la “Gestión del Mantenimiento” como técnicas complementarias para la toma de medidas correctoras y preventivas. Por último se abordan los casos de estudio considerados como puntos de referencia en el campo de investigación para la aplicación del sistema propuesto. La tercera parte incluye el capítulo siete, el cual constituye el corazón de la tesis. En este capítulo se presenta el esquema o sistema general de diagnosis de fallos propuesto. El sistema es dividido en tres partes: construcción de los modelos de diagnosis, validación de los modelos y aplicación on-line. Además incluye un modulo de detección de fallos previo a la diagnosis y una metodología de detección de anomalías para la detección de nuevos fallos. Por último, de este sistema se desglosan varias metodologías para procesos continuos y por lote. La cuarta parte de esta tesis presenta la validación de las metodologías propuestas. Específicamente, el capítulo ocho presenta la validación de las metodologías propuestas para su aplicación en procesos continuos y el capítulo nueve presenta la validación de las metodologías correspondientes a los procesos por lote. El capítulo diez valida la metodología de detección de anomalías en procesos por lote reales. Primero es aplicada a un intercambiador de calor escala laboratorio y después su aplicación es escalada a un proceso Foto-Fenton de planta piloto, lo cual corrobora el potencial y éxito de la metodología en la práctica real. Finalmente, la quinta parte de esta tesis, compuesta por el capítulo once, es dedicada a presentar y reafirmar las conclusiones finales y las principales contribuciones de la tesis. Además, se plantean las líneas de investigación futuras y se lista el trabajo desarrollado y presentado durante el periodo de investigación

Applications of ISES for vegetation and land use

Remote sensing relative to applications involving vegetation cover and land use is reviewed to consider the potential benefits to the Earth Observing System (Eos) of a proposed Information Sciences Experiment System (ISES). The ISES concept has been proposed as an onboard experiment and computational resource to support advanced experiments and demonstrations in the information and earth sciences. Embedded in the concept is potential for relieving the data glut problem, enhancing capabilities to meet real-time needs of data users and in-situ researchers, and introducing emerging technology to Eos as the technology matures. These potential benefits are examined in the context of state-of-the-art research activities in image/data processing and management

Learning Informative Health Indicators Through Unsupervised Contrastive Learning

Condition monitoring is essential to operate industrial assets safely and efficiently. To achieve this goal, the development of robust health indicators has recently attracted significant attention. These indicators, which provide quantitative real-time insights into the health status of industrial assets over time, serve as valuable tools for fault detection and prognostics. In this study, we propose a novel and universal approach to learn health indicators based on unsupervised contrastive learning. Operational time acts as a proxy for the asset's degradation state, enabling the learning of a contrastive feature space that facilitates the construction of a health indicator by measuring the distance to the healthy condition. To highlight the universality of the proposed approach, we assess the proposed contrastive learning framework in two distinct tasks - wear assessment and fault detection - across two different case studies: a milling machines case study and a real condition monitoring case study of railway wheels from operating trains. First, we evaluate if the health indicator is able to learn the real health condition on a milling machine case study where the ground truth wear condition is continuously measured. Second, we apply the proposed method on a real case study of railway wheels where the ground truth health condition is not known. Here, we evaluate the suitability of the learned health indicator for fault detection of railway wheel defects. Our results demonstrate that the proposed approach is able to learn the ground truth health evolution of milling machines and the learned health indicator is suited for fault detection of railway wheels operated under various operating conditions by outperforming state-of-the-art methods. Further, we demonstrate that our proposed approach is universally applicable to different systems and different health conditions

Signal Processing and Classification Tools for Intelligent Distributed Monitoring and Analysis of the Smart Grid

This paper proposes a novel framework for an intelligent monitoring system that supervises the performance of the future power system. The increased complexity of the power system could endanger the reliability, voltage quality, operational security or resilience of the power system. A distributed structure for such a monitoring system is described and some of the advanced signal processing techniques or tools that could be used in such a monitoring system are given. Several examples for seeking the spatial locations and finding the underlying causes of disturbances are included