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

Maintenance Management of Wind Turbines

“Maintenance Management of Wind Turbines” considers the main concepts and the state-of-the-art, as well as advances and case studies on this topic. Maintenance is a critical variable in industry in order to reach competitiveness. It is the most important variable, together with operations, in the wind energy industry. Therefore, the correct management of corrective, predictive and preventive politics in any wind turbine is required. The content also considers original research works that focus on content that is complementary to other sub-disciplines, such as economics, finance, marketing, decision and risk analysis, engineering, etc., in the maintenance management of wind turbines. This book focuses on real case studies. These case studies concern topics such as failure detection and diagnosis, fault trees and subdisciplines (e.g., FMECA, FMEA, etc.) Most of them link these topics with financial, schedule, resources, downtimes, etc., in order to increase productivity, profitability, maintainability, reliability, safety, availability, and reduce costs and downtime, etc., in a wind turbine. Advances in mathematics, models, computational techniques, dynamic analysis, etc., are employed in analytics in maintenance management in this book. Finally, the book considers computational techniques, dynamic analysis, probabilistic methods, and mathematical optimization techniques that are expertly blended to support the analysis of multi-criteria decision-making problems with defined constraints and requirements

Methods and Systems for Fault Diagnosis in Nuclear Power Plants

This research mainly deals with fault diagnosis in nuclear power plants (NPP), based on a framework that integrates contributions from fault scope identification, optimal sensor placement, sensor validation, equipment condition monitoring, and diagnostic reasoning based on pattern analysis. The research has a particular focus on applications where data collected from the existing SCADA (supervisory, control, and data acquisition) system is not sufficient for the fault diagnosis system. Specifically, the following methods and systems are developed. A sensor placement model is developed to guide optimal placement of sensors in NPPs. The model includes 1) a method to extract a quantitative fault-sensor incidence matrix for a system; 2) a fault diagnosability criterion based on the degree of singularities of the incidence matrix; and 3) procedures to place additional sensors to meet the diagnosability criterion. Usefulness of the proposed method is demonstrated on a nuclear power plant process control test facility (NPCTF). Experimental results show that three pairs of undiagnosable faults can be effectively distinguished with three additional sensors selected by the proposed model. A wireless sensor network (WSN) is designed and a prototype is implemented on the NPCTF. WSN is an effective tool to collect data for fault diagnosis, especially for systems where additional measurements are needed. The WSN has distributed data processing and information fusion for fault diagnosis. Experimental results on the NPCTF show that the WSN system can be used to diagnose all six fault scenarios considered for the system. A fault diagnosis method based on semi-supervised pattern classification is developed which requires significantly fewer training data than is typically required in existing fault diagnosis models. It is a promising tool for applications in NPPs, where it is usually difficult to obtain training data under fault conditions for a conventional fault diagnosis model. The proposed method has successfully diagnosed nine types of faults physically simulated on the NPCTF. For equipment condition monitoring, a modified S-transform (MST) algorithm is developed by using shaping functions, particularly sigmoid functions, to modify the window width of the existing standard S-transform. The MST can achieve superior time-frequency resolution for applications that involves non-stationary multi-modal signals, where classical methods may fail. Effectiveness of the proposed algorithm is demonstrated using a vibration test system as well as applications to detect a collapsed pipe support in the NPCTF. The experimental results show that by observing changes in time-frequency characteristics of vibration signals, one can effectively detect faults occurred in components of an industrial system. To ensure that a fault diagnosis system does not suffer from erroneous data, a fault detection and isolation (FDI) method based on kernel principal component analysis (KPCA) is extended for sensor validations, where sensor faults are detected and isolated from the reconstruction errors of a KPCA model. The method is validated using measurement data from a physical NPP. The NPCTF is designed and constructed in this research for experimental validations of fault diagnosis methods and systems. Faults can be physically simulated on the NPCTF. In addition, the NPCTF is designed to support systems based on different instrumentation and control technologies such as WSN and distributed control systems. The NPCTF has been successfully utilized to validate the algorithms and WSN system developed in this research. In a real world application, it is seldom the case that one single fault diagnostic scheme can meet all the requirements of a fault diagnostic system in a nuclear power. In fact, the values and performance of the diagnosis system can potentially be enhanced if some of the methods developed in this thesis can be integrated into a suite of diagnostic tools. In such an integrated system, WSN nodes can be used to collect additional data deemed necessary by sensor placement models. These data can be integrated with those from existing SCADA systems for more comprehensive fault diagnosis. An online performance monitoring system monitors the conditions of the equipment and provides key information for the tasks of condition-based maintenance. When a fault is detected, the measured data are subsequently acquired and analyzed by pattern classification models to identify the nature of the fault. By analyzing the symptoms of the fault, root causes of the fault can eventually be identified

Eddy current defect response analysis using sum of Gaussian methods

This dissertation is a study of methods to automatedly detect and produce approximations of eddy current differential coil defect signatures in terms of a summed collection of Gaussian functions (SoG). Datasets consisting of varying material, defect size, inspection frequency, and coil diameter were investigated. Dimensionally reduced representations of the defect responses were obtained utilizing common existing reduction methods and novel enhancements to them utilizing SoG Representations. Efficacy of the SoG enhanced representations were studied utilizing common Machine Learning (ML) interpretable classifier designs with the SoG representations indicating significant improvement of common analysis metrics

Modeling and Optimal Operation of Hydraulic, Wind and Photovoltaic Power Generation Systems

The transition to 100% renewable energy in the future is one of the most important ways of achieving "carbon peaking and carbon neutrality" and of reducing the adverse effects of climate change. In this process, the safe, stable and economical operation of renewable energy generation systems, represented by hydro-, wind and solar power, is particularly important, and has naturally become a key concern for researchers and engineers. Therefore, this book focuses on the fundamental and applied research on the modeling, control, monitoring and diagnosis of renewable energy generation systems, especially hydropower energy systems, and aims to provide some theoretical reference for researchers, power generation departments or government agencies

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

Optimización de procesos industriales con técnicas de Minería de Datos: mantenimiento de aerogeneradores y fabricación con tecnologías láser

En este trabajo se emplean técnicas de Minería de Datos para mejorar la eficiencia de dos procesos industriales: el diagnóstico de fallos en aerogeneradores y la fabricación de piezas metálicas de geometría compleja mediante tecnologías láser. Se mejora la validación experimental de estudios anteriores, en los que no se usó validación cruzada ni se tuvieron en cuenta algunas particularidades de los problemas analizados. Para el diagnóstico de fallos en aerogeneradores, se identifica la técnica de clasificación más adecuada para relacionar medidas de vibraciones con el tipo de fallo. Además, se define la métrica más adecuada para evaluar su precisión. Para la fabricación de piezas metálicas de geometría compleja, se estima la técnica de clasificación más adecuada para predecir la calidad superficial obtenida con pulido superficial láser, así como la técnica de regresión para predecir los errores en los distintos requerimientos geométricos de piezas obtenidas mediante microfresado 3D láser.Ministerio de Economía y Competitividad, proyecto TIN-2011-24046

Marine Power Systems

Marine power systems have been designed to be a safer alternative to stationary plants in order to adhere to the regulations of classification societies. Marine steam boilers recently achieved 10 MPa pressure, in comparison to stationary plants, where a typical boiler pressure of 17 MPa was the standard for years. The latest land-based, ultra-supercritical steam boilers reach 25 MPa pressure and 620 °C temperatures, which increases plant efficiency and reduces fuel consumption. There is little chance that such a plant concept could be applied to ships. The reliability of marine power systems has to be higher due to the lack of available spare parts and services that are available for shore power systems. Some systems are still very expensive and are not able to be widely utilized for commercial merchant fleets such as COGAS, mainly due to the high cost of gas turbines. Submarine vehicles are also part of marine power systems, which have to be reliable and accurate in their operation due to their distant control centers. Materials that are used in marine environments are prone to faster corrosive wear, so special care also should be taken in this regard. The main aim of this Special Issue is to discuss the options and possibilities of utilizing energy in a more economical way, taking into account the reliability of such a system in operation

Identifying and Detecting Attacks in Industrial Control Systems

The integrity of industrial control systems (ICS) found in utilities, oil and natural gas pipelines, manufacturing plants and transportation is critical to national wellbeing and security. Such systems depend on hundreds of field devices to manage and monitor a physical process. Previously, these devices were specific to ICS but they are now being replaced by general purpose computing technologies and, increasingly, these are being augmented with Internet of Things (IoT) nodes. Whilst there are benefits to this approach in terms of cost and flexibility, it has attracted a wider community of adversaries. These include those with significant domain knowledge, such as those responsible for attacks on Iran’s Nuclear Facilities, a Steel Mill in Germany, and Ukraine’s power grid; however, non specialist attackers are becoming increasingly interested in the physical damage it is possible to cause. At the same time, the approach increases the number and range of vulnerabilities to which ICS are subject; regrettably, conventional techniques for analysing such a large attack space are inadequate, a cause of major national concern. In this thesis we introduce a generalisable approach based on evolutionary multiobjective algorithms to assist in identifying vulnerabilities in complex heterogeneous ICS systems. This is both challenging and an area that is currently lacking research. Our approach has been to review the security of currently deployed ICS systems, and then to make use of an internationally recognised ICS simulation testbed for experiments, assuming that the attacking community largely lack specific ICS knowledge. Using the simulator, we identified vulnerabilities in individual components and then made use of these to generate attacks. A defence against these attacks in the form of novel intrusion detection systems were developed, based on a range of machine learning models. Finally, this was further subject to attacks created using the evolutionary multiobjective algorithms, demonstrating, for the first time, the feasibility of creating sophisticated attacks against a well-protected adversary using automated mechanisms