Reciprocating compressor prognostics of an instantaneous failure mode utilising temperature only measurements

Journal article


Loukopoulos, P, Zolkiewski, G, Bennet, I, Sampath, S, Pilidis, P, Duan, F, Sattar, TP and Mba, D (2017). Reciprocating compressor prognostics of an instantaneous failure mode utilising temperature only measurements. Applied Acoustics.
AuthorsLoukopoulos, P, Zolkiewski, G, Bennet, I, Sampath, S, Pilidis, P, Duan, F, Sattar, TP and Mba, D
Abstract

Reciprocating compressors are critical components in the oil and gas sector, though their maintenance cost is known to be relatively high. Compressor valves are the weakest component, being the most frequent failure mode, accounting for almost half the maintenance cost. One of the major targets in industry is minimisation of downtime and cost, while maximising availability and safety of a machine, with maintenance considered a key aspect in achieving this objective. The concept of Condition Based Maintenance and Prognostics and Health Management (CBM/PHM) which is founded on the diagnostics and prognostics principles, is a step towards this direction as it offers a proactive means for scheduling maintenance. Despite the fact that diagnostics is an established area for reciprocating compressors, to date there is limited information in the open literature regarding prognostics, especially given the nature of failures can be instantaneous. This work presents an analysis of prognostic performance of several methods (multiple linear regression, polynomial regression, K-Nearest Neighbours Regression (KNNR)), in relation to their accuracy and variability, using actual temperature only valve failure data, an instantaneous failure mode, from an operating industrial compressor. Furthermore, a variation for Remaining Useful Life (RUL) estimation based on KNNR, along with an ensemble technique merging the results of all aforementioned methods are proposed. Prior to analysis, principal components analysis and statistical process control were employed to create !! and ! metrics, which were proposed to be used as health indicators reflecting degradation process of the valve failure mode and are proposed to be used for direct RUL estimation for the first time. Results demonstrated that even when RUL is relatively short due to instantaneous nature of failure mode, it is feasible to perform good RUL estimates using the proposed techniques.

Keywordsreciprocating compressor; valve; prognostics; remaining useful life; multiple linear regression; polynomial regression; K-nearest neighbours,; instantaneous failure; principal components analysis; statistical process control; 0203 Classical Physics; 0913 Mechanical Engineering; 1201 Architecture; Acoustics
Year2017
JournalApplied Acoustics
PublisherElsevier
ISSN0003-682X
Digital Object Identifier (DOI)doi:10.1016/j.apacoust.2017.12.003
Publication dates
Print14 Dec 2017
Publication process dates
Deposited19 Mar 2018
Accepted10 Dec 2017
Accepted author manuscript
License
CC BY-NC-ND 4.0
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Khan, A, Memon, S and Sattar, TP (2017). Integration and management of solar energy for electric vehicle charging station. Solar World Congress 2017 - Innovation for the 100% renewable energy transformation. Abu Dhabi, UAE 29 Oct - 02 Nov 2017 London South Bank University.
Climbing Robots for NDT Applications
Al Rashed, M, Kimball, M, Vega, L, Vera, D, Soler, J, Correa, M, Garcia, A, Virk, GS and Sattar, TP (2017). Climbing Robots for NDT Applications. 20th International Conference on Climbing and Walking Robots and Support Technologies for Mobile Machines, CLAWAR 2017. Porto, Portugal 11 - 13 Sep 2017 London South Bank University. doi:https://doi.org/10.1142/9789813231047_0036
Reciprocating compressor prognostics
Loukopoulos, P, Sampath, S, Plidis, P, Zolkiewski, G, Bennett, I, Duan, F, Sattar, TP and Mba, D (2017). Reciprocating compressor prognostics. CMSM 2017 7th International Congress Design and Modelling of Mechanical Systems. Hammamet, Tunisia 27 - 29 Mar 2017 London South Bank University.
Design and Optimization of Permanent Magnet Based Adhesion Module for Robots Climbing on Reinforced Concrete Surfaces
Howlader, MOF and Sattar, TP (2016). Design and Optimization of Permanent Magnet Based Adhesion Module for Robots Climbing on Reinforced Concrete Surfaces. in: Bi, Y, Kapoor, S and Bhatia, R (ed.) Intelligent Systems and Applications: Extended and Selected Results from the SAI Intelligent Systems Conference (IntelliSys) 2015 Springer. pp. 153-171
Numerical fitting-based likelihood calculation to speed up the particle filter
Li, T, Sun, S, Corchado, JM, Sattar, TP and Si, S (2016). Numerical fitting-based likelihood calculation to speed up the particle filter. International Journal of Adaptive Control and Signal Processing. 30 (11), pp. 1583-1602.
Non-destructive testing robots (NDTBOTS) for in-service storage tank inspection
Anvo, R, Sattar, TP, Gan, T and Pinson, I (2017). Non-destructive testing robots (NDTBOTS) for in-service storage tank inspection. Climbing and Walking Robots and the Support Technologies for Mobile Machines (CLAWAR). Porto Polytechnic, Portugal 11 - 13 Sep 2017
Helicopter Main Gearbox Bearing Defect Identification using Vibration and Acoustic Emission Techniques
Duan, F, Elasha, F, Greaves, M and Mba, D (2016). Helicopter Main Gearbox Bearing Defect Identification using Vibration and Acoustic Emission Techniques. P2016 IEEE International Conference on Prognostics and Health Management (ICPHM). Carleton University Ottawa, ON, Canada 20 - 22 Jun 2016 IEEE. doi:https://doi.org/10.1109/ICPHM.2016.7542856
Development of a Wall Climbing Robotic Ground Penetrating Radar System for Inspection of Vertical Concrete Structures
Sattar, TP, Howlader, MOF and Dudley, S (2016). Development of a Wall Climbing Robotic Ground Penetrating Radar System for Inspection of Vertical Concrete Structures. International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering. 10 (8), pp. 1346-1352.
Miniaturization of Dipole Antenna for Low Frequency Ground Penetrating Radar
Howlader, MOF and Sattar, TP (2016). Miniaturization of Dipole Antenna for Low Frequency Ground Penetrating Radar. Progress In Electromagnetics Research C (PIER C). 61, pp. 161-170.
Low Speed Bearing Condition Monitoring – A Case Study
Duan, F, Nze, I and Mba, D (2016). Low Speed Bearing Condition Monitoring – A Case Study. Proceedings of 2016 International Conference on Quality, Reliability, Risk, Maintenance, and Safety Engineering (QR2MSE 2016) and 2016 World Congress on Engineering Asset Management (WCEAM2016). Jiuzhaigou, Sichuan, China 25 - 28 Jul 2016 London South Bank University.
Canonical Variate Analysis for Performance Degradation under Faulty Conditions
Ruiz-Carcel, C, Lao, L, Cao, Y and Mba, D (2016). Canonical Variate Analysis for Performance Degradation under Faulty Conditions. Control Engineering Practice. 54, pp. 70-80.
Feasibility study on using thioether as an emergency backup lubrication system on a large helicopter main gearbox
Duan, F, Tee, S, Corsar, M, Healey, A, Kleine-Beek, W and Mba, D (2016). Feasibility study on using thioether as an emergency backup lubrication system on a large helicopter main gearbox. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science.
Helicopter Main Gearbox Bearing Defect Identification with Acoustic Emission Techniques
Duan, F, Elasha, F, Mba, D and Bennett, I (2016). Helicopter Main Gearbox Bearing Defect Identification with Acoustic Emission Techniques. IEEE International Conference on Prognostics and Health Management. Ottawa, Canada 20 - 22 Jun 2016 London South Bank University.
Induction Motor Parameter Estimation Using Sparse Grid Optimization Algorithm
Duan, F, Zivanovic, R, Al-Sarawi, S and Mba, D (2016). Induction Motor Parameter Estimation Using Sparse Grid Optimization Algorithm. IEEE Transactions on Industrial Informatics. PP (99).
A comparative study of the effectiveness of vibration and acoustic emission in diagnosing a defective bearing in a planetary gearbox
Elasha, F, Greaves, M, Mba, D and Duan, F (2016). A comparative study of the effectiveness of vibration and acoustic emission in diagnosing a defective bearing in a planetary gearbox. Applied Acoustics. 115, pp. 181-195.
A comparative study of adaptive filters and linear prediction in detecting a naturally degraded bearing within a gearbox; Case Studies in Mechanical Systems and Signal Processing
Elasha, F, Mba, D and Ruiz-Carcel, C (2015). A comparative study of adaptive filters and linear prediction in detecting a naturally degraded bearing within a gearbox; Case Studies in Mechanical Systems and Signal Processing. Case Studies in Mechanical Systems and Signal Processing. 3 (June), pp. 1-8.
Deployment of laser cutting head with wall climbing robot for nuclear decommissioning
Sattar, TP, Hilton, P and Howlader, MOF (2016). Deployment of laser cutting head with wall climbing robot for nuclear decommissioning. 19th International Conference on Climbing and Walking Robots and Support Technologies for Mobile Machines (CLAWAR 2016). London 12 - 14 Sep 2016 London South Bank University.
Fire suppression systems in aircraft: Their past, present & future
Benson, CM, Fernandez-Cerezo, G, Holborn, PG and Mba, D (2016). Fire suppression systems in aircraft: Their past, present & future. Fire Investigation. 1 (3), pp. 34-41.
Challenges for the development of EFFICIENT - An Environmentally Friendly Fire Suppression System for Cargo using Innovative Green Technology
Fernandez-Cerezo, G, Benson, CM, Holborn, PG and Mba, D (2016). Challenges for the development of EFFICIENT - An Environmentally Friendly Fire Suppression System for Cargo using Innovative Green Technology. Institute of Fire Engineers RE16. Birmingham Nov 2016 London South Bank University.
Comparison of MUSIC and ESPRIT DOA Estimation algorithms for Wireless Communications
Oumar, O A, Siyau, M F and Sattar, T. (2012). Comparison of MUSIC and ESPRIT DOA Estimation algorithms for Wireless Communications. The First International Conference on Future Generation Communication Technologies. London 12 - 14 Dec 2012