Energy efficiency-based predictive maintenance optimization

of centrifugal gas compressor using (DRL)

Abstract
In terms of sustainability, the secret to economic development in industrial systems these days
is energy. However, energy supplies are scarce and are becoming more and more costly.
Energy, saving is therefore an important challenge for industrial sectors, especially oil and gas
industry, and can assist to reduce both the cost of energy and effect on the environment. The
main task of optimizing maintenance is to device a maintenance strategy that rises equipment
obtainability and efficiency, controls the degree of degradation of equipment, confirm safe and
environmentally supported operation, reduces the total cost of operation, which means both
production and energy costs. Even, they are hardly explicitly considered in the predictive
models guiding energy saving policies, predictive maintenance optimization, operational
procedures be able to extend margins for increasing energy efficiency in the oil and gas
industry. The life-cycle expenses of centrifugal compressors used in the oil and gas sector are
typically dominated by energy costs. Therefore, this paper focuses on centrifugal gas
compressor performance degradation, considering energy efficiency as an indicator in the
decision-forcing method for maintenance. In the oil and gas industry, compressor maintenance
is vital as it is an essential device that operates continuously. Plant engineers currently
confronting hurdles in predicting the right time for maintenance and will generally adhere to
the recommendations of the original equipment manufacturer (OEM). In order to guide them
on the compressor maintenance and important steps to be taken, most plant engineers do not
have a predictive tool. In that way, we first developed the energy efficiency concept which is
known as EEI (energy efficiency indicator). To assess the EEI and its evolution, we propose a
generic formulation that considers static and dynamic factors of influence. In a predictive
maintenance goal, the evolution of this indicator regarding the deterioration of the centrifugal
gas compressor is analyzed. This leads to concept of energy efficiency performance called
REEL (remaining energy efficient life), demonstrating the remaining energy life. In a proactive
vision, the REEL could be used as a forecast approach in the maintenance decision-making
process. A predictive model will be developed to schedule maintenance activities for
centrifugal gas compressors by using AI technologies such as deep reinforcement learning
(DRL) for cost saving, maintenance automation, and downtime reduction to predict the
potential development of the EEI to determine REEL.

Keywords: Energy efficiency index (EEI), Remaining energy efficient life (REEL)
Artificial intelligence (AI), Predictive maintenance (PdM), deep reinforcement learning (DRL)
1. Introduction

For any industrial sector, saving of energy is most important matter, specifically for the oil and
gas industry, and it assist to cut off both energy costs and environmental impacts. Monitoring
techniques offer the possibility to increase energy efficiency, decrease running costs and reduce
emissions when properly developed [1]. Typically, energy price dominates the life cost of
centrifugal gas compressors operated in different industrial and municipal processes,
developing the compressor smart target for improving energy efficiency [2]. A centrifugal
compressor's typical function is to compress gas or air at a higher pressure. Centrifugal
compressor performance breakdown and deterioration can have a bad effect on the operation,
energy and profit of an enterprise or business that depends on continuous production.
Compared to axial compressors, the advantages of centrifugal compressors are mostly coupled
to robustness, a broad operational scale and comparatively minimal investing and maintenance
costs [3]. Typically, energy price affects the life cycle costs, while considering the total lifespan
costs of compressed-air equipment (LCC). Up to 80 % of the overall life cycle costs can be the
cost of energy. An example of a compressor's life-cycle cost is explained in Fig. 1.1 [4].

Figure. 1.1: Compressor life-cycle costs.

Compressor energy efficiency assessment is source for saving of energy and reducing carbon
emissions, it is also impartial process of impact evaluation of the compressor set's actual
operating efficiency. The manufacturer, or the third party can test their real performance in
different operating conditions with different working fluids for general power and refrigeration
compressors through set up test rigs for smaller compressor power, simpler operation condition
adjustment and easier gas component [5]. Energy savings can be achieved using energy-
efficient technologies, improvement of operations and efficient maintenance. A good strategy
for maintenance could improve energy efficiency, improve reliability, and decrease risk [6].
Maintenance as a key industry activity, with its significant cost and reliability impact, is
immensely influential in the ability of a company to be economical in low cost, high ranking
and performance. Any unscheduled downtime of machinery or equipment would degrade or
else disrupt the core business of a company, potentially causing in substantial fines and
immeasurable loss of reputation. Amazon, for example, experienced only 49 minutes of
stoppage, which in 2013 charge the company $4 million in lost sales. On regular, as per market
study by the Ponemon Institute, organizations drop $138,000 per hour owing to data center
interruption [7]. The main trial of, maintenance optimization is to device an appropriate
maintenance approach that increases equipment obtainability and efficiency, controls the
degree of deterioration of equipment, guarantees safe and environment friendly operations, and
reduces the entire cost of operation, which means equally production and energy costs [8].
Certain assumptions and constraints, such as high-level prevention/repair costs, insufficient or
inaccurate processes of mathematical deterioration and physical abstraction of features, suffer
from existing traditional maintenance strategies. Predictive maintenance is projected as a new
type of maintenance paradigm with the trend of smart production and evolution of the Internet
of Things (IoT), data mining and artificial Intelligence (AI), to execute maintenances, only after
the analytical models forecast certain failures or degradations [9]. As the oil and gas industry
faces growing pressure to reduce the emissions and environmental impacts of its operations
worldwide, the use of AI in energy efficiency and power quality is becoming increasingly
important. Analytics-driven machine learning-supported AI algorithms can discern patterns in
data that can signal opportunities in the afore mentioned assets to optimize energy utilization.
AI already offers powerful strategies for transforming human knowledge into software. Energy
efficiency analysis (EEA) and energy quality analysis (PQA) provide operators with both
savings and a competitive edge through energy optimization [10]. The advance of DRL and its
variations provide a promising method for efficient control in complex systems. Deep
Reinforcement Learning (DRL) is used for decision-making. DRL can cope with a
sophisticated state space with highly dynamic time variant environments that be able to be
leveraged to offer judgment support for a PdM system [11]. Intelligent sensors that all together
make up one of the major and most complete Internet of Things (IoT) of every industry in the
world are increasingly filling the modern-day oil and gas field and their pipeline and processing
plant connectivity to refineries [12]. Maintenance optimization and operational processes, even
if they are rarely specifically considered in the predictive models driving energy saving
policies, may deliver margins to improve energy efficiency in the oil and gas industry. To
ensure that the plant achieves the required efficiency, it is important to track operation of
maintenance and maintenance outcomes and the connection amongst the inputs and the output
of the maintenance process [13]. In this paper, the authors proposing methodology and
prediction tool be implemented to support in the decision-making technique for infrastructure
monitoring and maintenance by considering energy efficiency as an indicator. This approach
can also allow plant operators to track centrifugal gas compressor condition monitoring, energy
efficiency input in the form of electrical power and output in gas production, which is realistic
knowledge for improving predictive maintenance optimization.

2. Related work

The work of Mazzetti et al. [14] suggested new technologies such as bottoming cycles for
recovery of waste heat from the gas turbine and heat recovery from the compressor train for
gas export, to increase the energy efficiency of offshore oil and gas platforms. The results
showed that an improvement in energy efficiency of 33 percent corresponds to a reduction in
fuel consumption and CO2 release of 25 percent from 517 g CO2 / kW-hr. Bhat and Aaron
[15] proposed methods to increase centrifugal gas compressor energy efficiency such as anti-
fouling coating result in better performance over a longer period and the use of non-metallic
labyrinth seals that can achieve lower clearance and slightly deform. Qing Hui Lou1 et al [16]
developed model for energy efficiency analysis and proposed online energy efficiency analysis
and interactive electric gas scheduling optimization of offshore platform energy equipment
technology. Zagorowska et al [17] presented a data-driven algorithm for enhanced
turbomachinery estimation and prediction of a degradation indicator to predict the expected
value of deterioration and measure the uncertainty of the forecast, it combines a moving
window approach with adaptive regression analysis for energy saving. Safiyulla et al [18]
developed a diagnostic model to predict performance deterioration and to maintain centrifugal
gas compressors using genetic programming (GP). Some computer codes were created for
OEM isentropic and real isentropic heads of a gas compressor using a GP model in the recorded
study. As expected by the GP model, performance degradation showed an average RMSE of
7.95 percent. Thom et al [19] proposed risk-based maintenance (RBM) and condition-based
maintenance (CBM) for gas compressor model that allows the assessment of the actual failure
risk of a production device in the oil and gas industries.
Xu et al [20] worked on brief overview about the PdM system in the age of big data, with
specific focus on data-driven fault diagnostic and prognostic models, methods, and algorithms.
Xie et al [21] In view of the defects of the conventional fuzzy analytic hierarchy process
(FAHP), a fuzzy analytic hierarchy process (FAHP) based on target programming was
expected and the basic implementation process of this approach is defined in the selection of
transformer maintenance strategies. Ikuobase et al [22] three key elements of a maintenance
system were outlined, such as risk evaluation, maintenance plan selection and maintenance
task interval determination tools used in the reliability-centered maintenance maintenance
framework (RCM). Rao and Naikan [23] proposed condition-based maintenance strategy for
periodic online washing and inspection of gas turbine compressor offline washing by using the
Markov algorithm method to reduce total cost per hour. Zhao et al [24] using fuzzy curvelet
neural network based on fuzzy theory and wavelet neural network, maintenance costs,
performance, and failure rate predicted for petrochemical plants. Ahmed [25] reliability of the
components in the gas compression system was suggested, with maintenance behavior focused
on failure analysis using the optimization of intervention in the industrial centrifugal
compressor plant. Singh et al [26] proposed induction motor maintenance strategy considered
motor performance as a key indicator for fault identification and optimization of condition-
based maintenance (CBM) actions. The proposed approach lets maintenance workers schedule
maintenance action based on the expected motor running failure and its cost of repair. The
function of efficiency and condition monitoring is also enabled by this approach in reducing
the CO2 emission. Goman et al [27] determined the electric motor selection criteria based on
the minimum energy consumption status by considering the service cycle of centrifugal pump
units. Martinez et al [28] developed a deep reinforcement learning (DRL) for analyzing time
series, streaming data, and predicting their class mark early in time using as little data as
possible. Early classification of time series data is paramount for helping decision-makers in
real-world applications, ranging from predictive maintenance to personalized medicine. Ding
et al [29] suggested deep reinforcement learning (DRL) for end-to-end fault diagnosis
approach for rotating machinery. This technique significantly decreases the dependency for
fault diagnosis on previous expertise and expert experience. Data sets of two types of rotating
machinery, rolling bearings and hydraulic pumps containing several calculated raw vibration
signals under different health states and working conditions are used to perform validation tests
of the proposed process.
Yuankai et al [30] studied, the energy management of a series-parallel plug-in hybrid electric
bus (PHEB) based on deep deterministic policy gradients because of its power delivery
versatility. An actor-critical, model-free reinforcement learning algorithm that can allocate the
optimal energy split of the bus over continuous spaces is a deep determinist policy gradient.
Zhang et al [31] proposed the health indicator learning problem as a credit assignment
challenge and solved with deep reinforcement learning (DRL) based approaches. Therefore,
domain KPIs are not needed for the proposed method and are sufficiently generic to be applied
to equipment across industries. The RUL problem, which is one of the most complicated
problems in predictive maintenance optimization, solved by health indicators as a compact
representation. Rocchetta et al [32] developed reinforcement learning (RL) to optimally
manage the operation and maintenance of power grids equipped with forecasting and health
management capabilities. The knowledge about the health status of the grid components is
exploited by reinforcement learning. Optimal steps to optimize the expected benefit are
established, considering the aleatory ambient uncertainties. Houman et al [33] studied the
effect of compressor fouling and washing on the revenue of the gas turbine power plant, and a
general solution is analyzed for the optimum time between compressor washes under variable
fouling rates and demand power. Mohammad Omidi et al [34] developed a hybrid
optimization model based on genetic algorithms (GA) and a 3D simulation of compressors to
analyze certain parameters, such as blade angle at the leading and trailing edges and the starting
point of splitter blades. Sangj Cho et al [35] with case studies focused on the finite state
continuous time Markov model, linear regression system, and their hybrid model, it presents
three methods for predicting the next failure time of offshore plant equipment (gas
compressor).

3. Research Methodology

Herein research, we are aiming to encourage the improvement of traditional maintenance

judgment by considering the energy efficiency indicator to track and forecast the possible
failure to degrade or decrease in the energy performance of a centrifugal gas compressor. In
the proposed approach, maintenance action should be activated not only because of traditional
decision indicators such as age, reliability, physical degradation, etc., but also when more
energy is consumed by the compressor. To endorse the approach, the first objective is to use
conventional & sustainability indicator to collect the time-dependent output degradation of the
centrifugal gas compressor. The second objective is to use energy quality evaluation to develop
a performance measurement method for health monitoring of centrifugal gas compressors.
Finally, REEL may be used in a proactive vision as an effective predictor and forecasting
method for the maintenance decision-making process. A predictive model will be developed to
schedule maintenance activities for centrifugal gas compressors by applying artificial
intelligence (AI) technologies such as deep reinforcement learning (DRL) to maintenance
automation cost savings and downtime reduction in order to predict the future evolution of the
EEI, to measure REEL. The originally applicable documents on a specific gas compressor will
be compiled and studied. Product characteristics, operating specifications, and maintenance
histories of all sensors are details of interest. Research is carried out from these documents and
sensors to look at what defect occurs in what state or reading pattern compared to traditional
and sustainable. This became the foundation for software development an algorithm for the
program will be established after deciding the parameters and analyzing the relevant documents
and information from all the sensors available. With the collection of conventional and energy
data from the proposed gas compressor, the process of the program begins. These readings are
then correlated with the database's current readings. The program will produce the desired
outcome based on this and recommend the steps to be taken by the engineer or operator. It will
be checked by using the old database until the program is ready. The program is complete if it
is valid. Otherwise, the algorithm will be modified, and the program will be reviewed again.
Explain the suggested approach in Figure 3.1. The software known as Python is one of the most
popular high-level programming languages used in this analysis. It deals with variables, arrays,
artifacts, complicated arithmetic or Boolean expressions, and principles of computer science to
make it more detailed, thus increasing its usability exponentially. Artificial intelligence (AI)
and machine learning (ML) have prebuilt libraries such as NumPy for scientific computing,
SciPy for advanced computing and Pybrain, making it one of the best artificial intelligence
languages (AI). In order to achieve our goals of research and development of energy efficiency
index-based predictive maintenance optimization of centrifugal gas compressors, we will use
Python software with a deep reinforcement learning (DRL) predictive tool.
 Determining a primary energy efficiency performance model for centrifugal
gas compressor

Specifying the input and output parameters required for

predictive maintenance optimization

Selection of suitable sensors to be used in performance monitoring

Data acquisition (conventional & sustainable)

Data processing

No
Is data enough and adequate?

Yes

Training and testing DRL, implementing dependent and independent

data in model to cover all the possible fault scenarios

Analyze data from model output

No

Compare the result with similar works

or user experience and judgment, is
result satisfactory or not?

Yes

REEL analysis

Maintenance decision making support to EEP & REEL to proposed compressor

Figure. 3.1: Proposed methodology flow chart.

4 Conclusion and Future Recommendations

In this paper, we explored the idea of energy efficiency as a new indicator to be incorporated
into the maintenance decision-making process to help centrifugal gas compressor sustainability
requirements. In this way, EEI is symbolic of the value of the output of energy efficiency at a
given time. It can be expressed as the energy input ratio and this for various abstraction levels
over the useful output of the equipment. A strong emphasis was also put on the forecasting of
these impact factors through prognostic approaches to track the evolution of EEI times. This
leads to the proposal of a novel Remaining Energy Efficient Life (REEL) idea to provide the
time remaining before the EEI evolution reaches a particular threshold set in advance in terms
of technological and/or economic constraints. This research will assist plant engineers in the
making of maintenance scheduling decisions. Recommendations may be made from a
traditional as well as a sustainable point of view with high conviction. This would effectively
minimize process complexity and reduce downtime due to equipment failure or insufficient
time for the production process of parts from order to delivery. Predictive maintenance
optimization contributes a great deal to detecting early faults, preventing unforeseen outages,
improving overall efficiency, and reducing operational costs because certain assumptions and
limitations, such as high prevention/repair costs, insufficient or unreliable processes of
mathematical deterioration and manual extraction of features, are influenced by current
conventional maintenance approaches. The EE definition is symbolic of the sustainability
criteria that the industrial system must now fulfill in order to confront not only economic, but
also social and environmental challenges. There are many factors influencing the energy
efficiency of the centrifugal gas compressor, so studies on fouling and other degradation
mechanisms, i.e. erosion, corrosion, mechanical damage, surge events, and internal
recirculation, need to be conducted collectively or individually for potential recommendation.
 ACKNOWLEDGEMENT

Author is grateful to his Supervisor & Co AP Dr Masdi B Muhammad & AP Dr Zainal Ambri
and University Teknology Petronas for providing an opportunity to work in ideal research
environment.

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