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The demand for cost-effective, reliable and safe machinery operation requires accurate fault detection and classification to achieve an efficient maintenance strategy and increase performance. Furthermore, in strategic sectors such as the oil and gas industry, fault prediction plays a key role to extend component lifetime and reduce unplanned equipment thus preventing costly breakdowns and plant shutdowns. This paper presents the preliminary development of a simple and easy to implement machine learning (ML) model for early fault prediction of a centrifugal pump in the oil and gas industry. The data analysis is based on real-life historical data from process and equipment sensors mounted on the selected machinery. The raw sensor data, mainly from temperature, pressure and vibrations probes, are denoised, pre-processed and successively coded to train the model. To validate the learning capabilities of the ML model, two different algorithms—the Support Vector Machine (SVM) and the Multilayer Perceptron (MLP)—are implemented in KNIME platform. Based on these algorithms, potential faults are successfully recognized and classified ensuring good prediction accuracy. Indeed, results from this preliminary work show that the model allows us to properly detect the trends of system deviations from normal operation behavior and generate fault prediction alerts as a maintenance decision support system for operatives, aiming at avoiding possible incoming failures.

In this work, we report the feasibility study to predict the properties of neat crude oil samples from 300-MHz NMR spectral data and partial least squares (PLS) regression models. The study was carried out on 64 crude oil samples obtained from 28 different extraction fields and aims at developing a rapid and reliable method for characterizing the crude oil in a fast and cost-effective way. The main properties generally employed for evaluating crudes' quality and behavior during refining were measured and used for calibration and testing of the PLS models. Among these, the UOP characterization factor K (K(UOP)) used to classify crude oils in terms of composition, density (D), total acidity number (TAN), sulfur content (S), and true boiling point (TBP) distillation yields were investigated. Test set validation with an independent set of data was used to evaluate model performance on the basis of standard error of prediction (SEP) statistics. Model performances are particularly good for K(UOP) factor, TAN, and TPB distillation yields, whose standard error of calibration and SEP values match the analytical method precision, while the results obtained for D and S are less accurate but still useful for predictions. Furthermore, a strategy that reduces spectral data preprocessing and sample preparation procedures has been adopted. The models developed with such an ample crude oil set demonstrate that this methodology can be applied with success to modern refining process requirements.

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