Big data: From theory to practice - a maintenance ......Big data: From theory to practice - a...
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Big data: From theory to practice - a maintenance application on wind turbines
High Tech Meets Data ScienceFebruary 9, 2017
Alessandro Di Bucchianico
Joint work with Stella Kapodistriaand Thomas Kenbeek
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Thomas Kenbeek Winner SLF Award 2016
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http://www.servicelogisticsforum.nl/nl/nieuws/29/9e-slf-afstudeeprijs-voor-bachelor-scriptie
• Over 30 research groups from six different departments of TU/e– Very diverse mix of scientists, all interested in working with and
on real world data• Coordination & cooperation in research programs
– Customer journey– Health analytics– Internet of things– Quantified self– Smart manufacturing and maintenance
• Virtual center, with small own staff (2.2 FTE)– Scientific Director: Wil van de Aalst– Operational Director: Mark Mietus– Program Manager: Joos Buijs– Secretary / communication: Henriette de Haas / Patricia Knubben
Data Science Center Eindhoven
www.tue.nl/dsce
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• Window to the world: Inside-Out & Outside-In – By operating together we are more recognizable and easier
accessible both to companies as well as to (semi) governments (entry point, website, etc.)
– To influence the (inter)national agenda and to initiate larger initiatives (flagships, etc.) we need to collaborate.
– Representation in various DS bodies (DSPN, BDA, C2D, BVDA, etc.)
• Meeting place, connecting people, exchanging ideas– Meeting people from other disciplines and organizations (lectures,
summits, news, …)
DSC/e mission
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Google images
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Industrial setting
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4OFFSHORE
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Industrial setting
3G
HQ IJSSEL TECHNOLOGIES
SERVER
WEB SERVER
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Industrial setting
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Industrial setting
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Industrial setting
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Industrial setting
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Expected impact
Timely detection of failures Detection of complex failures (several causes / multiple failure modes) Empowerment van asset owner
Goal:Algorithmic approach to condition based maintenance
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Project Goals and Impact
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Condition Based MaintenanceModel elements• deteriorating/degradation mechanisms• failure types• monitoring schemes (for condition of device/system)• maintenance actions
What is the objective?• optimal maintenance time• proper maintenance action (minimal, corrective,. . . )• optimal inspection scheme (when to inspect, how many samples to
collect?)
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Problem statement: detailsData:• Component condition
– Temperature– Vibration
• Speed• Pitch angle• Yaw• Operating state• Power output
• Environmental conditions
• Event & maintenance logs
Data from every turbine :3GB per day*365 days=1.095TB per year
Objective:Monitoring, prognostics and diagnostics of wind turbines
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Step 1: Identify baseline period (19 June 2013 – 18 Oct 2013)
Step 2: Only look at main generator operating & connected
Step 3: Build an algorithm considering all available relevant data
Step 4: Verification
From data to maintenance
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Model Single component
(perfect, good, failed)
Monitoring instances
Noise ~N(0,𝜎𝜎2)
Time
Cond
ition
State of the component
Perfect
Good
Failed
Objective: identify in a timely fashion the change of the condition
Approach:
Consider a baseline (perfect state)
Derive upper and lower alarm limits (not specification limits!)
The approach resembles multidimensional Statistical Process Control (SPC)
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3G
HQ IJSSEL TECHNOLOGIES
SERVERPARKOWNER
WEB SERVER
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Current Approach – Static Limits
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Regression Approach
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Bearing monitoring: temperature
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Step 1: Identify in-control period (19 June 2013 – 18 Oct 2013)
Step 2: Only look at main generator (working)
Step 3: Build algorithm
Bearing monitoring: temperature
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Model Warnings for imminent failure
Nacelle temperature Oct-Nov 2013
Oil temperature Oct-Nov 2013
Bearing temperature Oct-Nov 2013
Gearbox temperature Oct-Nov 2013
Main gen. temperature Oct-Nov 2013
Starting gen. temperature Oct-Nov 2013
Power output main gen. Oct-Nov 2013
Power output starting gen. None
Prediction of Dec 2014 failure
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Results
Time
Cond
ition
State of the component
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1. Automated alarms based on dynamic joint thresholds for– Bearing– Gearbox– Generator
2. Overall health index 3. Power output prediction
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Practical Issues• sanity checks on data
– coding of missing data (0, 999,…)– variables with trivial behaviour– different names for variables for different customers– recalibration of sensors– unspecified time zone + summer/winter time
• pre-processing of data– binning and averaging of data (kills system dynamics)– undocumented approach to vibration data
• ownership of data (OEM versus park owner)• different settings after maintenance (e.g., RPM generator)• ...
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5Vs of big data
5Vs of big
data
Volume
Velocity
VarietyValue
Veracity
Ron Kenett and Galit Shmueli
Increase InfoQ at the Design stage Post-data collection stage
by assessing the InfoQ - Eight Dimensions Data resolution Data structure Data integration Temporal relevance Chronology of data and goal Generalizability Construct operationalization Communication
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Veracity, Information quality — InfoQQuality is evaluated in terms of the usefulness of the statistics for a particular goal.
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Further refinements• involve layout of wind park (position of wind turbine)• involve control policy of wind park• go from warnings to alarms• EWMA / CUSUM charts• .....
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Key Insights
1. Use dynamic thresholds based on joint use of measured quantities:– reduction of false alarms– timely detection of complex failures
2. Combine techniques of CBM and SPC :– data collection from CBM may be beneficial for SPC activities and
vice-versa– detection of out-of-control situations may avoid situations that
have increased failure rates
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