On Using Machine Learning to Early Detect Catastrophic Failures in Marine Diesel Engines

Open-access datasets for marine-engine predictive maintenance remain scarce, particularly those from controlled fault experiments with documented operating conditions, subsystem-level interventions and system-level measurements. This work presents the Marine Engine Fault Dataset, an openly available dataset from a turbocharged, intercooled three-cylinder marine diesel engine operated on a testbed under both reference and fault-scenario conditions. The experimental campaign combined a reference-performance program across the 30-90% load range with scenario-based tests in which abnormal conditions were introduced after stabilized fault-free operation, enabling controlled comparison between baseline and fault-affected behaviour. Five anomaly classes were implemented through physical interventions affecting major engine subsystems: cooling-water pump cavitation, compressor air-filter clogging, air-cooler fouling, injection-valve nozzle clogging and turbine degradation induced through increased exhaust-side restriction. The released data comprise multi-sensor time-series of operating, thermal, pressure, flow and combustion-related variables, with a separate reference-performance record and metadata for structured reuse. Technical validation shows that the reference measurements remain physically coherent across the operating range and that the imposed anomalies produce interpretable response patterns consistent with the affected subsystems, including progressively distinguishable behaviour where different severities were implemented. By combining controlled fault realization, multi-load operation and system-level measurements within a real marine-engine platform, the dataset provides a well-documented benchmark for anomaly detection, fault diagnosis, degradation modelling and related condition-monitoring studies in maritime machinery.

Machinery fault detection (MFD) remains heavily reliant on supervised learning, which struggles with the scarcity of fault labels in real-world settings. While reinforcement learning (RL) offers a framework to model the sequential nature of degradation, current ``RL-based'' MFD methods reduce the problem to a static contextual bandit (CB) formulation: by ignoring state transitions and discarding the temporal discount factor, they collapse to standard supervised classification. We propose an adversarial inverse reinforcement learning (AIRL) framework that treats MFD as an offline IRL problem. Unlike reconstruction-based approaches that rely on static error margins, or CBs that ignore dynamics, our method recovers an intrinsic "health" reward directly from observational state transitions, requiring neither manual reward engineering nor fault labels. On three run-to-failure benchmarks (HUMS2023, IMS, XJTU-SY), AIRL is the only method achieving non-saturated post-detection consistency across all datasets, while CB baselines fail to detect gradual degradation and reconstruction models collapse into always-anomalous states. Code and data: https://github.com/dhirajneupane/AIRL-MFD-DN.

Reliable marine-engine fault diagnosis in maritime IoT is challenged by distributed data ownership, heterogeneous fault distributions, and continuously changing operating conditions. This paper proposes SeaCausal-FL, a federated fuzzy causal learning framework that combines a shared temporal diagnostic path with mechanism-conditioned causal reasoning. An interval type-2 fuzzy layer represents uncertain and overlapping operating mechanisms, while each mechanism is associated with a physics-constrained structural causal model. Before aggregation, locally learned mechanisms are aligned using operating context, causal structure, and conditional intervention-response signatures. Model parameters are then aggregated according to sample, class, mechanism, and mechanism-class evidence instead of client sample size alone. The learned structural equations further support interval counterfactual reasoning through abduction, action, and prediction. Experiments on a marine-engine fault dataset and a real-data-calibrated semi-synthetic causal benchmark show that SeaCausal-FL achieves an average F1 score of 87.07% across four client partitions, with AUROC and AUPRC of 98.98% and 94.81%, respectively. It also maintains strong performance under unseen loads and fault-type omission during training. On the causal benchmark, SeaCausal-FL reaches an Edge-F1 of approximately 0.58 and an Edge-AUPRC of 0.68, reduces coefficient RMSE to about 0.14, and provides favorable counterfactual estimation and intervention decisions.