Operational optimization of networks of compressors considering condition-based maintenance

The paper presents a mixed integer linear programming model which deals with the optimal operation and maintenance of networks of compressors of chemical plants. This optimization model considers condition-based maintenance which involves the degradation of the condition of the compressors. The paper focuses on online and offline washing, two different cleaning procedures which reduce the extra power used by the compressors due to fouling. The state-of-the-art has demonstrated the optimal schedule of the maintenance of a single compressor neglecting the interactions between operation and maintenance of more than one compressor. The suggested optimization model studies a compressor station with multiple compressors and provides their optimal schedule and the best decisions for their washing. Different case scenarios examine the influence of different types of washing methods on the total costs of operation and maintenance. The paper demonstrates the benefits of the optimization and demonstrates that maintenance and operation have to be examined simultaneously and not separately, in contrast to common industrial practice and previous approaches in the literature

Optimization of a network of compressors in parallel: Operational and maintenance planning – The air separation plant case

A general mathematical framework for the optimization of compressors operations in air separation plants that considers operating constraints for compressors, several types of maintenance policies and managerial aspects is presented. The proposed approach can be used in a rolling horizon scheme. The operating status, the power consumption, the startup and the shutdown costs for compressors, the compressor-to-header assignments as well as the outlet mass flow rates for compressed air and distillation products are optimized under full demand satisfaction. The power consumption in the compressors is expressed by regression functions that have been derived using technical and historical data. Several case studies of an industrial air separation plant are solved. The results demonstrate that the simultaneous optimization of maintenance and operational tasks of the compressors favor the generation of better solutions in terms of total costs

Planning of production and utility systems under unit performance degradation and alternative resource-constrained cleaning policies

A general optimization framework for the simultaneous operational planning of utility and production systems is presented with the main purpose of reducing the energy needs and material resources utilization of the overall system. The proposed mathematical model focuses mainly on the utility system and considers for the utility units: (i) unit commitment constraints, (ii) performance degradation and recovery, (iii) different types of cleaning tasks (online or offline, and fixed or flexible time-window), (iv) alternative options for cleaning tasks in terms of associated durations, cleaning resources requirements and costs, and (v) constrained availability of resources for cleaning operations. The optimization function includes the operating costs for utility and production systems, cleaning costs for utility systems, and energy consumption costs. Several case studies are presented in order to highlight the applicability and the significant benefits of the proposed approach. In particular, in comparison with the traditional sequential planning approach for production and utility systems, the proposed integrated approach can achieve considerable reductions in startup/shutdown and cleaning costs, and most importantly in utilities purchases, as it is shown in one of the case studies

Electrical Loads and Power Systems for the DEMO Nuclear Fusion Project

EU-DEMO is a European project, having the ambitious goal to be the first demonstrative power plant based on nuclear fusion. The electrical power that is expected to be produced is in the order of 700–800 MW, to be delivered via a connection to the European High Voltage electrical grid. The initiation and control of fusion processes, besides the problems related to the nuclear physics, need very complex electrical systems. Moreover, also the conversion of the output power is not trivial, especially because of the inherent discontinuity in the EU-DEMO operations. The present article concerns preliminary studies for the feasibility and realization of the nuclear fusion power plant EU-DEMO, with a special focus on the power electrical systems. In particular, the first stage of the study deals with the survey and analysis of the electrical loads, starting from the steady-state loads. Their impact is so relevant that could jeopardy the efficiency and the convenience of the plant itself. Afterwards, the loads are inserted into a preliminary internal distribution grid, sizing the main electrical components to carry out the power flow analysis, which is based on simulation models implemented in the DIgSILENT PowerFactory software

A cost function for the natural gas transmission industry: further considerations

This article studies the cost function for the natural gas transmission industry. In addition to a tribute to H.B. Chenery, it firstly offers some further comments on a recent contribution (Yépez, 2008): a statistical characterization of long-run scale economies, and a simple reformulation of the long-run problem. An extension is then proposed to analyze how the presence of seasonally-varying flows modifies the optimal design of a transmission infrastructure. Lastly, the case of a firm that anticipates a possible random rise in its future output is also studied to discuss the optimal degree of excess capacity to be built into a new transmission infrastructure

Integrated plant monitoring to improve plant operation strategy and results

The more and more demanding conditions in the power generation sector requires to apply all the available technologies to optimize processes and reduce costs. An integrated asset management strategy, combining technical analysis and operation and maintenance management can help to improve plant performance, flexibility and reliability. In order to deploy such a model it is necessary to combine plant data and specific equipment condition information, with different systems devoted to analyze performance and equipment condition, and take advantage of the results to support operation and maintenance decisions. This model that has been dealt in certain detail for electricity transmission and distribution networks, is not yet broadly extended in the power generation sector, as proposed in this study for the case of a combined power plant. Its application would turn in direct benefit for the operation and maintenance and for the interaction to the energy marke

Multiobjective genetic algorithm strategies for electricity production from generation IV nuclear technology

Development of a technico-economic optimization strategy of cogeneration systems of electricity/hydrogen, consists in finding an optimal efficiency of the generating cycle and heat delivery system, maximizing the energy production and minimizing the production costs. The first part of the paper is related to the development of a multiobjective optimization library (MULTIGEN) to tackle all types of problems arising from cogeneration. After a literature review for identifying the most efficient methods, the MULTIGEN library is described, and the innovative points are listed. A new stopping criterion, based on the stagnation of the Pareto front, may lead to significant decrease of computational times, particularly in the case of problems involving only integer variables. Two practical examples are presented in the last section. The former is devoted to a bicriteria optimization of both exergy destruction and total cost of the plant, for a generating cycle coupled with a Very High Temperature Reactor (VHTR). The second example consists in designing the heat exchanger of the generating turbomachine. Three criteria are optimized: the exchange surface, the exergy destruction and the number of exchange modules

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

Assessing the Technical Specifications of Predictive Maintenance: A Case Study of Centrifugal Compressor

Dependability analyses in the design phase are common in IEC 60300 standards to assess the reliability, risk, maintainability, and maintenance supportability of specific physical assets. Reliability and risk assessment uses well-known methods such as failure modes, effects, and criticality analysis (FMECA), fault tree analysis (FTA), and event tree analysis (ETA)to identify critical components and failure modes based on failure rate, severity, and detectability. Monitoring technology has evolved over time, and a new method of failure mode and symptom analysis (FMSA) was introduced in ISO 13379-1 to identify the critical symptoms and descriptors of failure mechanisms. FMSA is used to estimate monitoring priority, and this helps to determine the critical monitoring specifications. However, FMSA cannot determine the effectiveness of technical specifications that are essential for predictive maintenance, such as detection techniques (capability and coverage), diagnosis (fault type, location, and severity), or prognosis (precision and predictive horizon). The paper proposes a novel predictive maintenance (PdM) assessment matrix to overcome these problems, which is tested using a case study of a centrifugal compressor and validated using empirical data provided by the case study company. The paper also demonstrates the possible enhancements introduced by Industry 4.0 technologies.publishedVersio

Exploring Prognostic and Diagnostic Techniques for Jet Engine Health Monitoring: A Review of Degradation Mechanisms and Advanced Prediction Strategies

Maintenance is crucial for aircraft engines because of the demanding conditions to which they are exposed during operation. A proper maintenance plan is essential for ensuring safe flights and prolonging the life of the engines. It also plays a major role in managing costs for aeronautical companies. Various forms of degradation can affect different engine components. To optimize cost management, modern maintenance plans utilize diagnostic and prognostic techniques, such as Engine Health Monitoring (EHM), which assesses the health of the engine based on monitored parameters. In recent years, various EHM systems have been developed utilizing computational techniques. These algorithms are often enhanced by utilizing data reduction and noise filtering tools, which help to minimize computational time and efforts, and to improve performance by reducing noise from sensor data. This paper discusses the various mechanisms that lead to the degradation of aircraft engine components and the impact on engine performance. Additionally, it provides an overview of the most commonly used data reduction and diagnostic and prognostic techniques