The analysis of equipment degradation has traditionally developed in two main directions. One approach, of great interest for control system design, has been to consider that degradation causes fundamental changes to the behaviour of a system. Another approach, used in optimal maintenance planning and production scheduling, considers degradation as a separate process that affects performance but does not necessarily change the behaviour. This article provides a review of mathematical models of degradation that will facilitate the integration of degradation modelling into control and optimisation schemes. To this end, a new unified classification is proposed. It takes into account the influence of degradation on the behaviour of the system, as well as the factors influencing degradation. Understanding these mutual influences will enable improved optimization, design and operation of control systems. The flexibility of the proposed classification is demonstrated in an industrial application to a multi-product batch scheduling process.

Performance-based maintenance of machinery relies on detection and prediction of performance degradation. Degradation indicators calculated from process measurements need to be approximated with degradation models that smooth the variations in the measurements and give predictions of future values of the indicator. Existing models for performance degradation assume that the performance monotonically decreases with time. In consequence, the models yield suboptimal performance in performance-based maintenance as they do not take into account that performance degradation can reverse itself. For instance, deposits on the blades of a turbomachine can be self-cleaning in some conditions. In this study, a data-driven algorithm is proposed that detects if the performance degradation indicator is increasing or decreasing and adapts the model accordingly. A moving window approach is combined with adaptive regression analysis of operating data to predict the expected value of the performance degradation indicator and to quantify the uncertainty of predictions. The algorithm is tested on industrial performance degradation data from two independent offshore applications, and compared with four other approaches. The parameters of the algorithm are discussed and recommendations on the optimal choices are made. The algorithm proved to be portable and the results are promising for improving performance-based maintenance.

Normal practice in a compressor station with compressors in parallel is to allocate the mass flows equally. However, this strategy is not optimal if the compressors are not identical. A common reason why compressors become non-identical is because their performance degrades over time. Degradation increases the power necessary to run the compressor station and changes the optimal allocation of mass flows. This paper presents a framework for optimal operation in a compressor station with degrading compressors. The optimisation framework proposed in this work explicitly includes a model of degradation in the optimisation problem and analyses how the optimal load-sharing changes when the compressors are degrading. The optimisation framework was applied in an industrial case study of a compressor station in which three parallel compressors are subject to degradation. The case study confirms that it is possible to minimise the extra power consumption due to degradation by adjusting the operating conditions of the compressor station. The analysis also gives insights into the impact of degradation on the optimal solution when compressors work at their limits.

Performance deterioration in turbomachinery is an unwanted phenomenon that changes the behaviour of the system. It can be described by a degradation indicator based on deviations from expected values of process variables. Existing models assume that the degradation is strictly increasing with fixed convexity and that there are no additional changes during the considered operating period. This work proposes the use of an exponential trend approximation with shape adaptation and apply it in a moving window framework. The suggested method of adjustment makes it possible for the model to follow the evolution of the indicator over time. The approximation method is then applied for monitoring purposes, to predict future degradation. The influence of the tuning parameters on the accuracy of the algorithm is investigated and recommendations for the values are derived. Finally, directions for further work are proposed.