Priority analysis for risk factors of equipment in a hydraulic turbine generator unit

Study on Performance Evaluation and Prediction of Francis Turbine Units Considering Low-Quality Data and Variable Operating Conditions

The stable operation of the Francis turbine unit (FTU) determines the safety of the hydropower plant and the energy grid. The traditional FTU performance evaluation methods with a fixed threshold cannot avoid the influence of variable operating conditions. Meanwhile, anomaly samples and missing values in the low-quality on-site data distort the monitoring signals, which greatly affects the evaluation and prediction accuracy of the FTU. Therefore, an approach to the performance evaluation and prediction of the FTU considering low-quality data and variable operating conditions is proposed in this study. First, taking the variable operating conditions into consideration, a FTU on-site data-cleaning method based on DBSCAN is constructed to adaptively identify the anomaly samples. Second, the gate recurrent unit with decay mechanism (GRUD) and the Wasserstein generative adversarial network (WGAN) are combined to propose the GRUD–WGAN model for missing data imputation. Third, to reduce the impact of data randomness, the healthy-state probability model of the FTU is established based on the GPR. Fourth, the prediction model based on the temporal pattern attention–long short-term memory (TPA–LSTM) is constructed for accurate degradation trend forecasting. Ultimately, validity experiments were conducted with the on-site data set of a large FTU in production. The comparison experiments indicate that the proposed GRUD–WGAN has the highest accuracy at each data missing rate. In addition, since the cleaning and imputation improve the data quality, the TPA–LSTM-based performance indicator prediction model has great accuracy and generalization performance.

A hybrid reliability-centered maintenance approach for mining transportation machines: a real case in Esfahan

Purpose

The purpose of this study is to propose a hybrid reliability-centered maintenance (RCM) approach for mining transportation machines of a limestone complex, a real case in Esfahan, Iran.

Design/methodology/approach

Criteria for selecting critical machines were collected within literature and selected by decision-makers (DCs), and critical machines have been identified using the preference ranking organization method for enrichment of evaluations (PROMETHEE). Also, multi-criteria decision-making (MCDM) methods were used in addition to failure mode, effects and criticality analysis (FMECA) for selecting and prioritizing high-risk failures as well as optimizing the RCM performance. More specifically, the criteria of severity, detectability and frequency of occurrence were selected for risk assessment based on the previous studies, and were weighted using the analytic hierarchy process (AHP) method. Also, the technique for order of preference by similarity to ideal solution (TOPSIS) has been applied to prioritize failures' risk. Finally, the critical failures were inserted in the RCM decision-making worksheet and the required actions were determined for them.

Findings

According to the obtained values from PROMEHTEE method, the machine with code 739-7 was selected as the first priority and the most critical equipment. Further, based on results of TOPSIS method, the failure mode of “Lubrication hole clogging in crankpin bearing due poor quality oil,” “Deformation of main bearing due to overwork” and “The piston ring hotness due to unusual increase in the temperature of cylinder” have the highest risks among failure modes, respectively.

Originality/value

RCM has been deployed in various studies. However, in the current study, a hybrid MCDM-FMECA has been proposed to cope with high-risk failures. Besides, transportation machineries are one of the most critical equipment in the mining industry. Due to noticeable costs of this equipment, effective and continuous usage of this fleet requires the implementation of proper maintenance strategy. To the best of our knowledge, there is no research which has used RCM for transportation systems in the mining sector, and therefore, the innovation of this research is employment of the proposed hybrid approach for transportation machineries in the mining industry.