RECLAIM: Toward a New Era of Refurbishment and Remanufacturing of Industrial Equipment

Refurbishment and remanufacturing are the industrial processes whereby used products or parts that constitute the product are restored. Remanufacturing is the process of restoring the functionality of the product or a part of it to “as-new” quality, whereas refurbishment is the process of restoring the product itself or part of it to “like-new” quality, without being as thorough as remanufacturing. Within this context, the EU-funded project RECLAIM presents a new idea on refurbishment and remanufacturing based on big data analytics, machine learning, predictive analytics, and optimization models using deep learning techniques and digital twin models with the aim of enabling the stakeholders to make informed decisions about whether to remanufacture, upgrade, or repair heavy machinery that is toward its end-of-life. The RECLAIM project additionally provides novel strategies and technologies that enable the reuse of industrial equipment in old, renewed, and new factories, with the goal of saving valuable resources by recycling equipment and using them in a different application, instead of discarding them after use. For instance, RECLAIM provides a simulation engine using digital twin in order to predict maintenance needs and potential faults of large industrial equipment. This simulation engine keeps the virtual twins available to store all available information during the lifetime of a machine, such as maintenance operations, and this information can be used to perform an economic estimation of the machine's refurbishment costs. The RECLAIM project envisages developing new technologies and strategies aligned with the circular economy and in support of a new model for the management of large industrial equipment that approaches the end of its design life. This model aims to reduce substantially the opportunity cost of retaining strategies (both moneywise and resourcewise) by allowing relatively old equipment that faces the prospect of decommissioning to reclaim its functionalities and role in the overall production system

Asset management strategies for power electronic converters in transmission networks: Application to HVdc and FACTS devices

The urgency for an increased capacity boost bounded by enhanced reliability and sustainability through operating cost reduction has become the major objective of electric utilities worldwide. Power electronics have contributed to this goal for decades by providing additional flexibility and controllability to the power systems. Among power electronic based assets, high-voltage dc (HVdc) transmission systems and flexible ac transmission systems (FACTS) controllers have played a substantial role on sustainable grid infrastructure. Recent advancements in power semiconductor devices, in particular in voltage source converter based technology, have facilitated the widespread application of HVdc systems and FACTS devices in transmission networks. Converters with larger power ratings and higher number of switches have been increasingly deployed for bulk power transfer and large scale renewable integration—increasing the need of managing power converter assets optimally and in an efficient way. To this end, this paper reviews the state-of-the-art of asset management strategies in the power industry and indicates the research challenges associated with the management of high power converter assets. Emphasis is made on the following aspects: condition monitoring, maintenance policies, and ageing and failure mechanisms. Within this context, the use of a physics-of-failure based assessment for the life-cycle management of power converter assets is introduced and discussed

Lunar Surface Systems Supportability Technology Development Roadmap

The Lunar Surface Systems Supportability Technology Development Roadmap is a guide for developing the technologies needed to enable the supportable, sustainable, and affordable exploration of the Moon and other destinations beyond Earth. Supportability is defined in terms of space maintenance, repair, and related logistics. This report considers the supportability lessons learned from NASA and the Department of Defense. Lunar Outpost supportability needs are summarized, and a supportability technology strategy is established to make the transition from high logistics dependence to logistics independence. This strategy will enable flight crews to act effectively to respond to problems and exploit opportunities in an environment of extreme resource scarcity and isolation. The supportability roadmap defines the general technology selection criteria. Technologies are organized into three categories: diagnostics, test, and verification; maintenance and repair; and scavenge and recycle. Furthermore, "embedded technologies" and "process technologies" are used to designate distinct technology types with different development cycles. The roadmap examines the current technology readiness level and lays out a four-phase incremental development schedule with selection decision gates. The supportability technology roadmap is intended to develop technologies with the widest possible capability and utility while minimizing the impact on crew time and training and remaining within the time and cost constraints of the program

Condition Assessment, Remaining Useful Life Prediction and Life Extension Decision Making for Offshore Oil and Gas Assets

Offshore oil and gas assets are highly complex structures comprising of several components, designed to have a lifecycle of about 20 to 30 years of working under harsh operational and environmental conditions. These assets, during their operational lifetime, are subjected to various degradation mechanisms such as corrosion, erosion, wear, creep and fatigue cracks. In order to improve economic viability and increase profitability, many operators are looking at extending the lifespan of their assets beyond the original design life, thereby making life extension (LE) an increasingly critical and highly-discussed topic in the offshore oil and gas industry. In order to manage asset aging and meet the LE requirements, offshore oil and gas operators have adopted various approaches such as following maintenance procedures as advised by the original equipment manufacturer (OEM), or using the experience and expertise of engineers and inspectors. However, performing these activities often provides very limited value addition to operators during the LE period of operation. This paper aims to propose a systematic framework to help operators meet LE requirements while optimizing their cost structure. This framework establishes an integration between three individual life assessment modules, namely: condition assessment, remaining useful life (RUL) prediction and LE decision-making. The benefits of the proposed framework are illustrated through a case study involving a three-phase separator system on a platform which was constructed in the mid-1970s in West Africa. The results of this study affirm the effectiveness of this framework in minimizing catastrophic failures during the LE phase of operations, whilst ensuring compliance to regulatory requirements

A candidate architecture for monitoring and control in chemical transfer propulsion systems

To support the exploration of space, a reusable space-based rocket engine must be developed. This engine must sustain superior operability and man-rated levels of reliability over several missions with limited maintenance or inspection between flights. To meet these requirements, an expander cycle engine incorporating a highly capable control and health monitoring system is planned. Alternatives for the functional organization and the implementation architecture of the engine's monitoring and control system are discussed. On the basis of this discussion, a decentralized architecture is favored. The trade-offs between several implementation options are outlined and future work is proposed

A Lunar Surface System Supportability Technology Development Roadmap

This paper discusses the establishment of a Supportability Technology Development Roadmap as a guide for developing capabilities intended to allow NASA's Constellation program to enable a supportable, sustainable and affordable exploration of the Moon and Mars. Presented is a discussion of "supportability", in terms of space facility maintenance, repair and related logistics and a comparison of how lunar outpost supportability differs from the International Space Station. Supportability lessons learned from NASA and Department of Defense experience and their impact on a future lunar outpost is discussed. A supportability concept for future missions to the Moon and Mars that involves a transition from a highly logistics dependent to a logistically independent operation is discussed. Lunar outpost supportability capability needs are summarized and a supportability technology development strategy is established. The resulting Lunar Surface Systems Supportability Strategy defines general criteria that will be used to select technologies that will enable future flight crews to act effectively to respond to problems and exploit opportunities in a environment of extreme resource scarcity and isolation. This strategy also introduces the concept of exploiting flight hardware as a supportability resource. The technology roadmap involves development of three mutually supporting technology categories, Diagnostics Test & Verification, Maintenance & Repair, and Scavenging & Recycling. The technology roadmap establishes two distinct technology types, "Embedded" and "Process" technologies, with different implementation and thus different criteria and development approaches. The supportability technology roadmap addresses the technology readiness level, and estimated development schedule for technology groups that includes down-selection decision gates that correlate with the lunar program milestones. The resulting supportability technology roadmap is intended to develop a set of technologies with widest possible capability and utility with a minimum impact on crew time and training and remain within the time and cost constraints of the Constellation progra

A novel implementation of vibration signal decomposition for estimation of degradation in rotating plant

Effective and transparent monitoring of rotating plant assets is essential to the continued reliable operation of power stations. Rotating plant monitoring generally includes analysis of vibration signals, where operations and maintenance engineers use the output from vibration sensors to justify the continued operation of the plant or plan for maintenance interventions where necessary. One common approach to such vibration monitoring is the adoption of alarm driven strategies where certain operational or mechanical interventions are performed when thresholds are triggered due to deviations from a predefined operational envelope. This reactive intervention approach, however, does not provide operators or equipment manufacturers with any insight into the long-term degradation of a rotating plant item, which could be used to mitigate unplanned stoppages. This paper proposes the novel implementation of Empirical Mode Decomposition to boiler feed pump vibration signals, alongside subsequent statistical analysis of the decomposed signals to estimate time-frames associated with alarm violations and entry into predefined zones of operation. Such a technique provides pump operators with information that can be used to plan for future maintenance interventions and pump manufactures with insight into the likely degradation of their product during sustained operation

A Lunar Surface System Supportability Technology Development Roadmap

This paper discusses the establishment of a Supportability Technology Development Roadmap as a guide for developing capabilities intended to allow NASA s Constellation program to enable a supportable, sustainable and affordable exploration of the Moon and Mars. Presented is a discussion of supportability, in terms of space facility maintenance, repair and related logistics and a comparison of how lunar outpost supportability differs from the International Space Station. Supportability lessons learned from NASA and Department of Defense experience and their impact on a future lunar outpost is discussed. A supportability concept for future missions to the Moon and Mars that involves a transition from a highly logistics dependent to a logistically independent operation is discussed. Lunar outpost supportability capability needs are summarized and a supportability technology development strategy is established. The resulting Lunar Surface Systems Supportability Strategy defines general criteria that will be used to select technologies that will enable future flight crews to act effectively to respond to problems and exploit opportunities in an environment of extreme resource scarcity and isolation. This strategy also introduces the concept of exploiting flight hardware as a supportability resource. The technology roadmap involves development of three mutually supporting technology categories, Diagnostics Test and Verification, Maintenance and Repair, and Scavenging and Recycling. The technology roadmap establishes two distinct technology types, "Embedded" and "Process" technologies, with different implementation and thus different criteria and development approaches. The supportability technology roadmap addresses the technology readiness level, and estimated development schedule for technology groups that includes down-selection decision gates that correlate with the lunar program milestones. The resulting supportability technology roadmap is intended to develop a set of technologies with widest possible capability and utility with a minimum impact on crew time and training and remain within the time and cost constraints of the Constellation program