An experimental study of clogging fault diagnosis in heat exchangers based on vibration signals

The water-circulating heat exchangers employed in petrochemical industrials have attracted great attentions in condition monitoring and fault diagnosis. In this paper, an approach based on vibration signals is proposed. By the proposed method, vibration signals are collected for different conditions through various high-precision wireless sensors mounted on the surface of the heat exchanger. Furthermore, by analyzing the characteristics of the vibration signals, a database of fault patterns is established, which therefore provides a scheme for conditional monitoring of the heat exchanger. An experimental platform is set up to evaluate the feasibility and effectiveness of the proposed approach, and support vector machine based on dimensionless parameters is developed for fault classification. The results have shown that the proposed method is efficient and has achieved a high accuracy for benchmarking vibration signals under both normal and faulty conditions

CONDITION-BASED RISK ASSESSMENT STRATEGY AND ITS HEALTH INDICATOR WITH APPLICATION TO PUMPS AND COMPRESSORS

Large rotating machinery, such as centrifugal gas compressors and pumps, are widely applied as crucial components in the petrochemical industries. To enable in-time and effective maintenance of these machines, the concept of a health indicator is arousing great interest. A suitable health indicator indicates the overall health of the machinery and it is closely related to maintenance strategies and decision-making. It can be obtained either from near misses and incident data, or from real-time measured data. However, the existing health indicators have some limitations. On the one hand, the near misses and incident data may have been obtained from similar systems, reflecting population characteristics but not fully accounting for the individual features of the target system. On the other hand, the existing health indicators that use condition monitoring data, mainly focused on detecting incipient faults, and usually do not include financial cost factors when calculating the indicators. Therefore, there is the requirement to develop a single system "Health Indicator", that can show the health condition of a system in real-time, as well as the likely financial loss incurred when a fault is detected in the system, to assist operators on maintenance decision making. This project has developed such an integrated health indicator for rotating machinery. The integrated health indicator described in this thesis is extracted from a novel condition-based risk assessment strategy, which can be regarded as an integration of risk-based maintenance with improved conventional condition-based maintenance, with financial factors taken into account. The value of the health indicator is that it directly illustrates the risk to the system (or equipment), including likely financial loss, which makes it easier for operators to select the optimal time for maintenance or set alarm thresholds given the specific conditions in their companies or plants. This thesis provides a guide to set up an integrated maintenance model for large rotating machinery. It provides a useful reference for researchers working on condition-based fault detection and dynamic risk-based maintenance

Research of dimensionless index for fault diagnosis positioning based on EMD

Dimensionless index as a new theory tool has been applied in fault diagnosis study, which has shown some progress, however, it will cause some interference to the diagnosis results since no considering the influence of other noise jamming signal is given. Empirical Mode Decomposition (EMD) technique could extract effectively the fault characteristic signal of vibration data. In view of the noise jamming of dimensionless index in analyzing data, dimensionless index processing algorithms based on EMD is proposed. Firstly, EMD method is used to decompose the collected vibration signals, then the first few Intrinsic Mode Functions (IMF) components are obtained which contains the fault characteristic of vibration data, and the effects of other noise signal are removed at the same time. Secondly, fault diagnosis can be achieved by calculating dimensionless parameter values to the IMF components with characteristic signal of vibration data, and obtaining range of characteristic value of their dimensionless index, then diagnosing and analyzing fault characteristics of the equipment. The proposed method is applied to fault diagnosis test analysis of rotating machinery, and the experiment has shown that the proposed method is efficient and effective

Internet of things for disaster management: state-of-the-art and prospects

Disastrous events are cordially involved with the momentum of nature. As such mishaps have been showing off own mastery, situations have gone beyond the control of human resistive mechanisms far ago. Fortunately, several technologies are in service to gain affirmative knowledge and analysis of a disaster's occurrence. Recently, Internet of Things (IoT) paradigm has opened a promising door toward catering of multitude problems related to agriculture, industry, security, and medicine due to its attractive features, such as heterogeneity, interoperability, light-weight, and flexibility. This paper surveys existing approaches to encounter the relevant issues with disasters, such as early warning, notification, data analytics, knowledge aggregation, remote monitoring, real-time analytics, and victim localization. Simultaneous interventions with IoT are also given utmost importance while presenting these facts. A comprehensive discussion on the state-of-the-art scenarios to handle disastrous events is presented. Furthermore, IoT-supported protocols and market-ready deployable products are summarized to address these issues. Finally, this survey highlights open challenges and research trends in IoT-enabled disaster management systems. © 2013 IEEE

Classification of bearing faults through time-frequency analysis and image processing

The present work proposes a new technique for bearing fault classification that combines time-frequency analysis with image processing. This technique uses vibration signals from bearing housings to detect bearing conditions and classify the faults. By means of Empirical Mode Decomposition (EMD), each vibration signal is decomposed into Intrinsic Mode Functions (IMFs). Principal Components Analysis (PCA) is then performed on the matrix of the decomposed IMFs and the important principal components are chosen. The spectrogram is obtained for each component by means of the Short Time Fourier Transform (STFT) to obtain an image that represents the time-frequency relationship of the main components of the analyzed signal. Furthermore, Image Moments are extracted from the spectrogram images of principal components in order to obtain an array of features for each signal that can be handled by the classification algorithm. 8 images are selected for each signal and 17 moments for each image, so an array of 136 features is associated with every signal. Finally, the classification is performed using a standard machine learning technique, i.e. Support Vector Machine (SVM), in the proposed technique. The dataset used in this work include data collected for various rotating speeds and loads, in order to obtain a set of different operating conditions, by a Roller Bearing Faults Simulator. The results have shown that the developed technique provides classification effectively, with a single classifier, of bearing faults characterized by different rotating speeds and different loads

Reduction of impacts of oil and gas operations through intelligent maintenance solution

Impacts of oil and gas production operations are always very obvious when there is imbalanced operation, uncontrolled stoppage or catastrophic failure of the system during normal operations. These impacts may range from high flaring and venting of associated petroleum gas, oil release or spillage, equipment damage, fire outbreak to even fatality. Possible causes of imbalanced operations or system failure are categorised into process upset, system degradation, ineffective operation and maintenance procedures and human errors. Effective maintenance strategy integrates major components of the system; people (human factors), operation and maintenance procedures (process) and production plant (technology) to develop an intelligent maintenance solution that is capable of monitoring and detecting fault in the system at incipient stage before operational integrity is compromised. This paper deploys data-based analytics technique to develop condition-based predictive maintenance system to monitor, predict and classify performance of gas processing system. Exhaust gas temperature (EGT) of Gas Turbine Engine (GTE) is one of the operating and control parameters associated with efficiency of the GTE operation. The EGT is measured using several thermocouples, temperature sensors spaced equidistant around the circumference of the exhaust duct of the GTE. Neural network technique of multisensory data fusion is integrated with intelligent maintenance system to monitor performance of GTE, detect fault and classify performance of GTE to optimal, average and abnormal performance

Profitability, reliability and condition based monitoring of LNG floating platforms: a review

The efficiency and profitability of Floating, Production, Storage and Offloading platform (FPSO) terminals depends on various factors such as LNG liquefaction process type, system reliability and maintenance approach. This review is organized along the following research questions: (i) what are the economic benefit of FPSO and how does the liquefaction process type affect its profitability profile?, (ii) how to improve the reliability of the liquefaction system as key section? and finally (iii) what are the major CBM techniques applied on FPSO. The paper concluded the literature and identified the research shortcomings in order to improve profitability, efficiency and availability of FPSOs