A framework for effective management of condition based maintenance programs in the context of industrial development of E-Maintenance strategies

CBM (Condition Based Maintenance) solutions are increasingly present in industrial systems due to two main circumstances: rapid evolution, without precedents, in the capture and analysis of data and significant cost reduction of supporting technologies. CBM programs in industrial systems can become extremely complex, especially when considering the effective introduction of new capabilities provided by PHM (Prognostics and Health Management) and E-maintenance disciplines. In this scenario, any CBM solution involves the management of numerous technical aspects, that the maintenance manager needs to understand, in order to be implemented properly and effectively, according to the company’s strategy. This paper provides a comprehensive representation of the key components of a generic CBM solution, this is presented using a framework or supporting structure for an effective management of the CBM programs. The concept “symptom of failure”, its corresponding analysis techniques (introduced by ISO 13379-1 and linked with RCM/FMEA analysis), and other international standard for CBM open-software application development (for instance, ISO 13374 and OSA-CBM), are used in the paper for the development of the framework. An original template has been developed, adopting the formal structure of RCM analysis templates, to integrate the information of the PHM techniques used to capture the failure mode behaviour and to manage maintenance. Finally, a case study describes the framework using the referred template.Gobierno de Andalucía P11-TEP-7303 M

Diagnostics and prognostics utilising dynamic Bayesian networks applied to a wind turbine gearbox

The UK has the largest installed capacity of offshore wind and this is set to increase significantly in future years. The difficulty in conducting maintenance offshore leads to increased operation and maintenance costs compared to onshore but with better condition monitoring and preventative maintenance strategies these costs could be reduced. In this paper an on-line condition monitoring system is created that is capable of diagnosing machine component conditions based on an array of sensor readings. It then informs the operator of actions required. This simplifies the role of the operator and the actions required can be optimised within the program to minimise costs. The program has been applied to a gearbox oil testbed to demonstrate its operational suitability. In addition a method for determining the most cost effective maintenance strategy is examined. This method uses a Dynamic Bayesian Network to simulate the degradation of wind turbine components, effectively acting as a prognostics tool, and calculates the cost of various preventative maintenance strategies compared to purely corrective maintenance actions. These methods are shown to reduce the cost of operating wind turbines in the offshore environment

Airborne Advanced Reconfigurable Computer System (ARCS)

A digital computer subsystem fault-tolerant concept was defined, and the potential benefits and costs of such a subsystem were assessed when used as the central element of a new transport's flight control system. The derived advanced reconfigurable computer system (ARCS) is a triple-redundant computer subsystem that automatically reconfigures, under multiple fault conditions, from triplex to duplex to simplex operation, with redundancy recovery if the fault condition is transient. The study included criteria development covering factors at the aircraft's operation level that would influence the design of a fault-tolerant system for commercial airline use. A new reliability analysis tool was developed for evaluating redundant, fault-tolerant system availability and survivability; and a stringent digital system software design methodology was used to achieve design/implementation visibility

Architecting Integrated System Health Management for Airworthiness

Integrated System Health Management (ISHM) for Unmanned Aerial Systems (UAS) has been a new area of research - seeking to provide situational awareness to mission and maintenance operations, and for improved decision-making with increased self-autonomy. This research effort developed an analytic architecture and an associated discrete-event simulation using Arena to investigate the potential benefits of ISHM implementation onboard an UAS. The objective of this research is two-fold: firstly, to achieve continued airworthiness by investigating the potential extension of UAS expected lifetime through ISHM implementation, and secondly, to reduce life cycle costs by implementing a Condition-Based Maintenance (CBM) policy with better failure predictions made possible with ISHM. Through a series of design experiments, it was shown that ISHM presented the most cost-effective improvement over baseline systems in situations where the reliability of the UAS is poor (relative to manned systems) and the baseline sensor exhibited poor qualities in terms of missed detection and false alarm rates. From the simulation results of the test scenarios, it was observed that failure occurrence rates, sensor quality characteristics and ISHM performance specifications were significant factors in determining the output responses of the model. The desired outcome of this research seeks to provide potential designers with top-level performance specifications of an ISHM system based on specified airworthiness and maintenance requirements for the envisaged ISHM-enabled UAS

On the role of Prognostics and Health Management in advanced maintenance systems

The advanced use of the Information and Communication Technologies is evolving the way that systems are managed and maintained. A great number of techniques and methods have emerged in the light of these advances allowing to have an accurate and knowledge about the systems’ condition evolution and remaining useful life. The advances are recognized as outcomes of an innovative discipline, nowadays discussed under the term of Prognostics and Health Management (PHM). In order to analyze how maintenance will change by using PHM, a conceptual model is proposed built upon three views. The model highlights: (i) how PHM may impact the definition of maintenance policies; (ii) how PHM fits within the Condition Based Maintenance (CBM) and (iii) how PHM can be integrated into Reliability Centered Maintenance (RCM) programs. The conceptual model is the research finding of this review note and helps to discuss the role of PHM in advanced maintenance systems.EU Framework Programme Horizon 2020, 645733 - Sustain-Owner - H2020-MSCA-RISE-201

Space engine safety system

A rocket engine safety system was designed to initiate control procedures to minimize damage to the engine or vehicle or test stand in the event of an engine failure. The features and the implementation issues associated with rocket engine safety systems are discussed, as well as the specific concerns of safety systems applied to a space-based engine and long duration space missions. Examples of safety system features and architectures are given, based on recent safety monitoring investigations conducted for the Space Shuttle Main Engine and for future liquid rocket engines. Also, the general design and implementation process for rocket engine safety systems is presented

Framework for a space shuttle main engine health monitoring system

A framework developed for a health management system (HMS) which is directed at improving the safety of operation of the Space Shuttle Main Engine (SSME) is summarized. An emphasis was placed on near term technology through requirements to use existing SSME instrumentation and to demonstrate the HMS during SSME ground tests within five years. The HMS framework was developed through an analysis of SSME failure modes, fault detection algorithms, sensor technologies, and hardware architectures. A key feature of the HMS framework design is that a clear path from the ground test system to a flight HMS was maintained. Fault detection techniques based on time series, nonlinear regression, and clustering algorithms were developed and demonstrated on data from SSME ground test failures. The fault detection algorithms exhibited 100 percent detection of faults, had an extremely low false alarm rate, and were robust to sensor loss. These algorithms were incorporated into a hierarchical decision making strategy for overall assessment of SSME health. A preliminary design for a hardware architecture capable of supporting real time operation of the HMS functions was developed. Utilizing modular, commercial off-the-shelf components produced a reliable low cost design with the flexibility to incorporate advances in algorithm and sensor technology as they become available

Orbit transfer rocket engine technology program: Automated preflight methods concept definition

The possibility of automating preflight engine checkouts on orbit transfer engines is discussed. The minimum requirements in terms of information and processing necessary to assess the engine'e integrity and readiness to perform its mission were first defined. A variety of ways for remotely obtaining that information were generated. The sophistication of these approaches varied from a simple preliminary power up, where the engine is fired up for the first time, to the most advanced approach where the sensor and operational history data system alone indicates engine integrity. The critical issues and benefits of these methods were identified, outlined, and prioritized. The technology readiness of each of these automated preflight methods were then rated on a NASA Office of Exploration scale used for comparing technology options for future mission choices. Finally, estimates were made of the remaining cost to advance the technology for each method to a level where the system validation models have been demonstrated in a simulated environment

Intelligent Data Fusion for Applied Decision Support

Data fusion technologies are widely applied to support a real-time decision-making in complicated, dynamically changing environments. Due to the complexity in the problem domain, artificial intelligent algorithms, such as Bayesian inference and particle swarm optimization, are employed to make the decision support system more adaptive and cognitive. This dissertation proposes a new data fusion model with an intelligent mechanism adding decision feedback to the system in real-time, and implements this intelligent data fusion model in two real-world applications. The first application is designing a new sensor management system for a real-world and highly dynamic air traffic control problem. The main objective of sensor management is to schedule discrete-time, two-way communications between sensors and transponder-equipped aircraft over a given coverage area. Decisions regarding allocation of sensor resources are made to improve the efficiency of sensors and communications, simultaneously. For the proposed design, its loop nature takes account the effect of the current sensor model into the next scheduling interval, which makes the sensor management system able to respond to the dynamically changing environment in real-time. Moreover, it uses a Bayesian network as the mission manager to come up with operating requirements for each region every scheduling interval, so that the system efficiently balances the allocation of sensor resources according to different region priorities. As one of this dissertation\u27s contribution in the area of Bayesian inference, the resulting Bayesian mission manager is shown to demonstrate significant performance improvement in resource usage for prioritized regions such as a runway in the air traffic control application for airport surfaces. Due to wind\u27s importance as a renewable energy resource, the second application is designing an intelligent data-driven approach to monitor the wind turbine performance in real-time by fusing multiple types of maintenance tests, and detect the turbine failures by tracking the turbine maintenance statistics. The current focus has been on building wind farms without much effort towards the optimization of wind farm management. Also, under performing or faulty turbines cause huge losses in revenue as the existing wind farms age. Automated monitoring for maintenance and optimizing of wind farm operations will be a key element in the transition of wind power from an alternative energy form to a primary form. Early detection and prediction of catastrophic failures helps prevent major maintenance costs from occurring as well. I develop multiple tests on several important turbine performance variables, such as generated power, rotor speed, pitch angle, and wind speed difference. Wind speed differences are particularly effective in the detection of anemometer failures, which is a very common maintenance issue that greatly impacts power production yet can produce misleading symptoms. To improve the detection accuracy of this wind speed difference test, I discuss a new method to determine the decision boundary between the normal and abnormal states using a particle swarm optimization (PSO) algorithm. All the test results are fused to reach a final conclusion, which describes the turbine working status at the current time. Then, Bayesian inference is applied to identify potential failures with a percentage certainty by monitoring the abnormal status changes. This approach is adaptable to each turbine automatically, and is advantageous in its data-driven nature to monitor a large wind farm. This approach\u27s results have verified the effectiveness of detecting turbine failures early, especially for anemometer failures

Establishment of a novel predictive reliability assessment strategy for ship machinery

There is no doubt that recent years, maritime industry is moving forward to novel and sophisticated inspection and maintenance practices. Nowadays maintenance is encountered as an operational method, which can be employed both as a profit generating process and a cost reduction budget centre through an enhanced Operation and Maintenance (O&M) strategy. In the first place, a flexible framework to be applicable on complex system level of machinery can be introduced towards ship maintenance scheduling of systems, subsystems and components.;This holistic inspection and maintenance notion should be implemented by integrating different strategies, methodologies, technologies and tools, suitably selected by fulfilling the requirements of the selected ship systems. In this thesis, an innovative maintenance strategy for ship machinery is proposed, namely the Probabilistic Machinery Reliability Assessment (PMRA) strategy focusing towards the reliability and safety enhancement of main systems, subsystems and maintainable units and components.;In this respect, the combination of a data mining method (k-means), the manufacturer safety aspects, the dynamic state modelling (Markov Chains), the probabilistic predictive reliability assessment (Bayesian Belief Networks) and the qualitative decision making (Failure Modes and Effects Analysis) is employed encompassing the benefits of qualitative and quantitative reliability assessment. PMRA has been clearly demonstrated in two case studies applied on offshore platform oil and gas and selected ship machinery.;The results are used to identify the most unreliability systems, subsystems and components, while advising suitable practical inspection and maintenance activities. The proposed PMRA strategy is also tested in a flexible sensitivity analysis scheme.There is no doubt that recent years, maritime industry is moving forward to novel and sophisticated inspection and maintenance practices. Nowadays maintenance is encountered as an operational method, which can be employed both as a profit generating process and a cost reduction budget centre through an enhanced Operation and Maintenance (O&M) strategy. In the first place, a flexible framework to be applicable on complex system level of machinery can be introduced towards ship maintenance scheduling of systems, subsystems and components.;This holistic inspection and maintenance notion should be implemented by integrating different strategies, methodologies, technologies and tools, suitably selected by fulfilling the requirements of the selected ship systems. In this thesis, an innovative maintenance strategy for ship machinery is proposed, namely the Probabilistic Machinery Reliability Assessment (PMRA) strategy focusing towards the reliability and safety enhancement of main systems, subsystems and maintainable units and components.;In this respect, the combination of a data mining method (k-means), the manufacturer safety aspects, the dynamic state modelling (Markov Chains), the probabilistic predictive reliability assessment (Bayesian Belief Networks) and the qualitative decision making (Failure Modes and Effects Analysis) is employed encompassing the benefits of qualitative and quantitative reliability assessment. PMRA has been clearly demonstrated in two case studies applied on offshore platform oil and gas and selected ship machinery.;The results are used to identify the most unreliability systems, subsystems and components, while advising suitable practical inspection and maintenance activities. The proposed PMRA strategy is also tested in a flexible sensitivity analysis scheme