Sensors Data Analysis in Supervisory Control and Data Acquisition (SCADA) Systems to Foresee Failures with an Undetermined Origin

Design of Fire Risk Estimation Method Based on Facility Data for Thermal Power Plants

In this paper, we propose a data classification and analysis method to estimate fire risk using facility data of thermal power plants. To estimate fire risk based on facility data, we divided facilities into three states-Steady, Transient, and Anomaly-categorized by their purposes and operational conditions. This method is designed to satisfy three requirements of fire protection systems for thermal power plants. For example, areas with fire risk must be identified, and fire risks should be classified and integrated into existing systems. We classified thermal power plants into turbine, boiler, and indoor coal shed zones. Each zone was subdivided into small pieces of equipment. The turbine, generator, oil-related equipment, hydrogen (H2), and boiler feed pump (BFP) were selected for the turbine zone, while the pulverizer and ignition oil were chosen for the boiler zone. We selected fire-related tags from Supervisory Control and Data Acquisition (SCADA) data and acquired sample data during a specific period for two thermal power plants based on inspection of fire and explosion scenarios in thermal power plants over many years. We focused on crucial fire cases such as pool fires, 3D fires, and jet fires and organized three fire hazard levels for each zone. Experimental analysis was conducted with these data set by the proposed method for 500 MW and 100 MW thermal power plants. The data classification and analysis methods presented in this paper can provide indirect experience for data analysts who do not have domain knowledge about power plant fires and can also offer good inspiration for data analysts who need to understand power plant facilities.

A Compact IIoT System for Remote Monitoring and Control of a Micro Hydropower Plant

Remote monitoring and operation evaluation applications for industrial environments are modern and easy means of exploiting the provided resources of specific systems. Targeted micro hydropower plant functionalities (such as tracking and adjusting the values of functional parameters, real-time fault and cause signalizing, condition monitoring assurance, and assessments of the need for maintenance activities) require the design of reliable and efficient devices or systems. The present work describes the design and implementation procedure of an Industrial Internet of Things (IIoT) system configured for a basic micro hydropower plant architecture and assuring simple means of customization for plant differences in structure and operation. The designed system features a set of commonly used functions specific to micro hydropower exploitation, providing maximum performance and efficiency.

Systematic Literature Review on Visual Analytics of Predictive Maintenance in the Manufacturing Industry

The widespread adoption of cyber-physical systems and other cutting-edge digital technology in manufacturing industry production facilities may motivate stakeholders to embrace the idea of Industry 4.0. Some industrial companies already have different sensors installed on their machines; however, without proper analysis, the data collected is not useful. This systematic review's main goal is to synthesize the existing evidence on the application of predictive maintenance (PdM) with visual aids and to identify the key knowledge gaps in areas including utilities, power generation, industry, and energy consumption. After a thorough search and evaluation for relevancy, 37 documents were identified. Moreover, we identified the visual analytics of PdM, including anomaly detection, planning/scheduling, exploratory data analysis (EDA), and explainable artificial intelligence (XAI). The findings revealed that anomaly detection was a major domain in PdM-related works. We conclude that most of the literature lacks depth in terms of an overall framework that combines data-driven and knowledge-driven techniques of PdM in the manufacturing industry. Some works that utilized both techniques indicated promising results, but there is insufficient research on involving maintenance personnel's feedback in the latter stage of PdM architecture. Thus, there are still pertinent issues that need to be investigated, and limitations that need to be overcome before PdM is deployed with minimal human involvement.

A Configurable Monitoring, Testing, and Diagnosis System for Electric Power Plants

The specific equipment, installation and machinery infrastructure of an electric power system have always required specially designed data acquisition systems and devices to ensure their safe operation and monitoring. Besides maintenance, periodical upgrade must be ensured for these systems, to meet the current practical requirements. Monitoring, testing, and diagnosis altogether represent key activities in the development process of electric power elements. This work presents the detailed structure and implementation of a complex, configurable system which can assure efficient monitoring, testing, and diagnosis for various electric power infrastructures, with proven efficiency through a comprehensive set of experimental results obtained in real running conditions. The developed hardware and software implementation is a robust structure, optimized for acquiring a large variety of electrical signals, also providing easy and fast connection within the monitored environment. Its high level of configurability and very good price-performance ratio makes it an original and handy solution for electric power infrastructures.

Clustering at the Disposal of Industry 4.0: Automatic Extraction of Plant Behaviors

For two centuries, the industrial sector has never stopped evolving. Since the dawn of the Fourth Industrial Revolution, commonly known as Industry 4.0, deep and accurate understandings of systems have become essential for real-time monitoring, prediction, and maintenance. In this paper, we propose a machine learning and data-driven methodology, based on data mining and clustering, for automatic identification and characterization of the different ways unknown systems can behave. It relies on the statistical property that a regular demeanor should be represented by many data with very close features; therefore, the most compact groups should be the regular behaviors. Based on the clusters, on the quantification of their intrinsic properties (size, span, density, neighborhood) and on the dynamic comparisons among each other, this methodology gave us some insight into the system’s demeanor, which can be valuable for the next steps of modeling and prediction stages. Applied to real Industry 4.0 data, this approach allowed us to extract some typical, real behaviors of the plant, while assuming no previous knowledge about the data. This methodology seems very promising, even though it is still in its infancy and that additional works will further develop it.

Analyzing Particularities of Sensor Datasets for Supporting Data Understanding and Preparation

Data scientists spend much time with data cleaning tasks, and this is especially important when dealing with data gathered from sensors, as finding failures is not unusual (there is an abundance of research on anomaly detection in sensor data). This work analyzes several aspects of the data generated by different sensor types to understand particularities in the data, linking them with existing data mining methodologies. Using data from different sources, this work analyzes how the type of sensor used and its measurement units have an important impact in basic statistics such as variance and mean, because of the statistical distributions of the datasets. The work also analyzes the behavior of outliers, how to detect them, and how they affect the equivalence of sensors, as equivalence is used in many solutions for identifying anomalies. Based on the previous results, the article presents guidance on how to deal with data coming from sensors, in order to understand the characteristics of sensor datasets, and proposes a parallelized implementation. Finally, the article shows that the proposed decision-making processes work well with a new type of sensor and that parallelizing with several cores enables calculations to be executed up to four times faster.