Adopting machine learning and condition monitoring P-F curves in determining and prioritizing high-value assets for life extension

•A novel framework for prioritizing equipment toward life extension;•Combining the concept of P-F curve in condition monitoring with machine learning;•Adopting data mining and k-means clustering algorithms to determine most vulnerable equipment for end-of-life treatment;•To cluster equipment with similar degradation profiles and same safety performance requirements;•To validate the proposed models using the NASA’s publicly available datasets. Many machine learning algorithms and models have been proposed in the literature for predicting the remaining useful life (RUL) of systems and components that are subject to condition monitoring (CM). However, in cases where data is ubiquitous, identifying the most suitable equipment for life-extension based on CM data and RUL predictions is a rather challenging task. This paper proposes a technique for determining and prioritizing high-value assets for life-extension treatments when they reach the end of their useful life. The technique exploits the use of key concepts in machine learning (such as data mining and k-means clustering) in combination with an important tool from reliability-centered maintenance (RCM) called the potential-failure (P-F) curve. The RCM process identifies essential equipment within a plant which are worth monitoring, and then derives the P-F curves for equipment using CM and operational data. Afterwards, a new index called the potential failure interval factor (PFIF) is calculated for each equipment or unit, serving as a health indicator. Subsequently, the units are grouped in two ways: (i) a regression model in combination with suitably defined PFIF window boundaries, (ii) a k-means clustering algorithm based on equipment with similar data features. The most suitable equipment for life-extension are identified in groups in order to aid in planning, decision-making and deployment of maintenance resources. Finally, the technique is empirically tested on NASA’s Commercial Modular Aero-Propulsion System Simulation datasets and the results are discussed in detail.