An Integrated Optimization Framework for Multi-Component Predictive Analytics in Wind Farm Operations & Maintenance

Recent years have seen an unprecedented growth in the use of sensor data to guide wind farm operations and maintenance. Emerging sensor-driven approaches typically focus on optimal maintenance procedures for single turbine systems, or model multiple turbines in wind farms as single component entities. In reality, turbines are composed of multiple components that dynamically interact throughout their lifetime. These interactions are central for realistic assessment and control of turbine failure risks. In this paper, an integrated framework that combines i) real-time degradation models used for predicting remaining life distribution of each component, with ii) mixed integer optimization models and solution algorithms used for identifying optimal wind farm maintenance and operations is proposed. Maintenance decisions identify optimal times to repair every component, which in turn, determine the failure risk of the turbines. More specifically, optimization models that characterize a turbine's failure time as the first time that one of its constituent components fail - a systems reliability concept called competing risk is developed. The resulting turbine failures impact the optimization of wind farm operations and revenue. Extensive experiments conducted for multiple wind farms with 300 wind turbines - 1200 components - showcases the performance of the proposed framework over conventional methods

Reliability-based economic model predictive control for generalized flow-based networks including actuators' health-aware capabilities

This paper proposes a reliability-based economic model predictive control (MPC) strategy for the management of generalized flow-based networks, integrating some ideas on network service reliability, dynamic safety stock planning, and degradation of equipment health. The proposed strategy is based on a single-layer economic optimisation problem with dynamic constraints, which includes two enhancements with respect to existing approaches. The first enhancement considers chance-constraint programming to compute an optimal inventory replenishment policy based on a desired risk acceptability level, leading to dynamically allocate safety stocks in flow-based networks to satisfy non-stationary flow demands. The second enhancement computes a smart distribution of the control effort and maximises actuators’ availability by estimating their degradation and reliability. The proposed approach is illustrated with an application of water transport networks using the Barcelona network as the considered case study.Peer ReviewedPostprint (author's final draft

Development and Application of a Digital Twin for Chiller Plant Performance Assessment

As the complexity of industrial equipment continues to increase, the management of the individual machines and integrated operations becomes difficult without computer tools. The availability of streaming data from manufacturing floors, plant operations, and deployed fleets can be overwhelming to analyze, although it provides opportunities to improve performance. The use of dedicated monitoring systems in the plant and field to troubleshoot machinery can be integrated within a product lifecycle management (PLM) architecture to offer greater features. PLM offers virtual processes and software tools for the design, analysis, monitoring, and support of engineering systems and products. Within this paradigm, a digital twin can estimate system behavior based on the assembled physical models and the operating data for preventive maintenance efforts. PLM software can store computer-aided-design, computer-aided-engineering, advanced manufacturing, and data in cloud form for remote access. Integrating physical and performance data into a single database provides flexibility and adaptability while allowing distant commanding and health monitoring of dynamic systems. The recent attention on global warming, and the minimization of energy consumption can be partially addressed by examining those economic sectors that use large quantities of electric power. Across the United States, heating, ventilation, and air conditioning (HVAC) systems use a collective $14 Billion of resources to control the temperature of commercial and residential spaces. A typical commercial HVAC system consists of a chiller plant, water pumps for fluid circulation, multiple heat exchangers, and iii forced air blowers. In this research project, a digital twin is created for a single compressor chilled water-based HVAC system using a multi-disciplinary CAE software package. The system level models are assembled to describe a 1400 ton chiller located in the East-side chiller plant on the Clemson University (Clemson, SC) campus. The dynamic models that estimate the fluid pressures, temperatures, and flow rates, as well as the electrical and mechanical power consumption, are validated against the operating data streamed through the OptiCX System. To demonstrate the capabilities of this digital twin tool in a preventive maintenance mode, various degradations are virtually investigated in the chiller plant\u27s components. The mechanical pump efficiency, electric pump motor friction, pipe blockage, air flow rate sensor, and the expansion valve opening were degraded by 3% to 5%, which impacted component behavior and system performance. The analysis of these predicted plant signals helped to establish preventive maintenance thresholds on these components, which should promote improved plant reliability. A digital twin provides additional flexibility than stand-alone monitoring technologies due to the capability of simulating customized scenarios for analyzing failure-prone conditions and overall equipment effectiveness (OEE). The PLM-based digital twin offers a design and prognostic platform for HVAC systems

A Simulation Based Approach for Determining Maintenance Strategies

Manufacturing organizations are continuously in the mode of identifying and implementing mechanisms to achieve a competitive edge. To this point manufacturers have recognized the critical role of equipment in the productivity of manufacturing operations. With the current trend of manufacturers attempting to lean out their production processes, primary and auxiliary equipment have become even more important to manufacturers as measured by productivity, quality, delivery, and cost metrics. As a result of the focus on lean manufacturing, maintenance management has found a new vigor and purpose to increase equipment capacity and capability. However, the most proactive maintenance strategy is not always the most effective utilization of resources. It is typical for manufacturers to integrate both reactive and proactive maintenance to define a cost effective maintenance strategy. A simulation-based approach is presented that allows an end user to develop such a maintenance strategy

Condition based maintenance optimization for multi-state wind power generation systems under periodic inspection

As the wind power system moves toward more efficient operation, one of the main challenges for managers is to determine a cost effective maintenance strategy. Most maintenance optimization studies for wind power generation systems deal with wind turbine components separately. However, there are economic dependencies among wind turbines and their components. In addition, most current researches assume that the components in a wind turbine only have two states, while condition monitoring techniques can often provide more detailed health information of components. This study aims to construct an optimal condition based maintenance model for a multi-state wind farm under the condition that individual components or subsystems can be monitored in periodic inspection. The results are demonstrated using a numerical example.info:eu-repo/semantics/publishedVersio

Practical Methods for Optimizing Equipment Maintenance Strategies Using an Analytic Hierarchy Process and Prognostic Algorithms

Many large organizations report limited success using Condition Based Maintenance (CbM). This work explains some of the causes for limited success, and recommends practical methods that enable the benefits of CbM. The backbone of CbM is a Prognostics and Health Management (PHM) system. Use of PHM alone does not ensure success; it needs to be integrated into enterprise level processes and culture, and aligned with customer expectations. To integrate PHM, this work recommends a novel life cycle framework, expanding the concept of maintenance into several levels beginning with an overarching maintenance strategy and subordinate policies, tactics, and PHM analytical methods. During the design and in-service phases of the equipment’s life, an organization must prove that a maintenance policy satisfies specific safety and technical requirements, business practices, and is supported by the logistic and resourcing plan to satisfy end-user needs and expectations. These factors often compete with each other because they are designed and considered separately, and serve disparate customers. This work recommends using the Analytic Hierarchy Process (AHP) as a practical method for consolidating input from stakeholders and quantifying the most preferred maintenance policy. AHP forces simultaneous consideration of all factors, resolving conflicts in the trade-space of the decision process. When used within the recommended life cycle framework, it is a vehicle for justifying the decision to transition from generalized high-level concepts down to specific lower-level actions. This work demonstrates AHP using degradation data, prognostic algorithms, cost data, and stakeholder input to select the most preferred maintenance policy for a paint coating system. It concludes the following for this particular system: A proactive maintenance policy is most preferred, and a predictive (CbM) policy is more preferred than predeterminative (time-directed) and corrective policies. A General Path prognostic Model with Bayesian updating (GPM) provides the most accurate prediction of the Remaining Useful Life (RUL). Long periods between inspections and use of categorical variables in inspection reports severely limit the accuracy in predicting the RUL. In summary, this work recommends using the proposed life cycle model, AHP, PHM, a GPM model, and embedded sensors to improve the success of a CbM policy

A Model for Maintenance Planning and Process Quality Control Optimization Based on EWMA and CUSUM Control Charts

The performance of a production system is highly dependent on the smooth operation of various equipment and processes. Thus, reducing failures of the equipment and processes in a cost-effective manner improves overall performance; this is often achieved by carrying out maintenance and quality control policies. In this study, an integrated optimization method that addresses both maintenance strategies and quality control practices is proposed using an exponentially weighted moving average (EWMA) chart, in which both corrective and preventive maintenance policies are considered. The integrated model has been proposed to find optimal decision variables of both the process quality decision parameters and the optimal interval of preventive maintenance (i.e., Ns, Hs, L, λ, and t_PM) to result in overall optimal expected hourly total system costs. A case study is then utilized to investigate the impact of cost criteria on the proposed integrated model and to compare the proposed model with a model using the cumulative sum (CUSUM) control chart. The improved model outputs indicate that there is a reduction of 34.6% in the total expected costs compared with those of the other model using the CUSUM chart. Finally, an analysis of sensitivity to present the effectiveness of the model parameters and the main variables in the overall costs of the system is provided