A probabilistic model for information and sensor validation

This paper develops a new theory and model for information and sensor validation. The model represents relationships between variables using Bayesian networks and utilizes probabilistic propagation to estimate the expected values of variables. If the estimated value of a variable differs from the actual value, an apparent fault is detected. The fault is only apparent since it may be that the estimated value is itself based on faulty data. The theory extends our understanding of when it is possible to isolate real faults from potential faults and supports the development of an algorithm that is capable of isolating real faults without deferring the problem to the use of expert provided domain-specific rules. To enable practical adoption for real-time processes, an any time version of the algorithm is developed, that, unlike most other algorithms, is capable of returning improving assessments of the validity of the sensors as it accumulates more evidence with time. The developed model is tested by applying it to the validation of temperature sensors during the start-up phase of a gas turbine when conditions are not stable; a problem that is known to be challenging. The paper concludes with a discussion of the practical applicability and scalability of the model

Chapter A Framework for Learning System for Complex Industrial Processes

Due to the intense price-based global competition, rising operating cost, rapidly changing economic conditions and stringent environmental regulations, modern process and energy industries are confronting unprecedented challenges to maintain profitability. Therefore, improving the product quality and process efficiency while reducing the production cost and plant downtime are matters of utmost importance. These objectives are somewhat counteracting, and to satisfy them, optimal operation and control of the plant components are essential. Use of optimization not only improves the control and monitoring of assets, but also offers better coordination among different assets. Thus, it can lead to extensive savings in the energy and resource consumption, and consequently offer reduction in operational costs, by offering better control, diagnostics and decision support. This is one of the main driving forces behind developing new methods, tools and frameworks. In this chapter, a generic learning system architecture is presented that can be retrofitted to existing automation platforms of different industrial plants. The architecture offers flexibility and modularity, so that relevant functionalities can be selected for a specific plant on an as-needed basis. Various functionalities such as soft-sensors, outputs prediction, model adaptation, control optimization, anomaly detection, diagnostics and decision supports are discussed in detail

Prognostic Algorithms for Condition Monitoring and Remaining Useful Life Estimation

To enable the benets of a truly condition-based maintenance philosophy to be realised, robust, accurate and reliable algorithms, which provide maintenance personnel with the necessary information to make informed maintenance decisions, will be key. This thesis focuses on the development of such algorithms, with a focus on semiconductor manufacturing and wind turbines. An introduction to condition-based maintenance is presented which reviews dierent types of maintenance philosophies and describes the potential benets which a condition- based maintenance philosophy will deliver to operators of critical plant and machinery. The issues and challenges involved in developing condition-based maintenance solutions are discussed and a review of previous approaches and techniques in fault diagnostics and prognostics is presented. The development of a condition monitoring system for dry vacuum pumps used in semi- conductor manufacturing is presented. A notable feature is that upstream process mea- surements from the wafer processing chamber were incorporated in the development of a solution. In general, semiconductor manufacturers do not make such information avail- able and this study identies the benets of information sharing in the development of condition monitoring solutions, within the semiconductor manufacturing domain. The developed solution provides maintenance personnel with the ability to identify, quantify, track and predict the remaining useful life of pumps suering from degradation caused by pumping large volumes of corrosive uorine gas. A comprehensive condition monitoring solution for thermal abatement systems is also presented. As part of this work, a multiple model particle ltering algorithm for prog- nostics is developed and tested. The capabilities of the proposed prognostic solution for addressing the uncertainty challenges in predicting the remaining useful life of abatement systems, subject to uncertain future operating loads and conditions, is demonstrated. Finally, a condition monitoring algorithm for the main bearing on large utility scale wind turbines is developed. The developed solution exploits data collected by onboard supervisory control and data acquisition (SCADA) systems in wind turbines. As a result, the developed solution can be integrated into existing monitoring systems, at no additional cost. The potential for the application of multiple model particle ltering algorithm to wind turbine prognostics is also demonstrated

Gas turbine engine condition monitoring using Gaussian mixture and hidden Markov models

This paper investigates the problem of condition monitoring of complex dynamic systems, specifically the detection, localisation and quantification of transient faults. A data driven approach is developed for fault detection where the multidimensional data sequence is viewed as a stochastic process whose behaviour can be described by a hidden Markov model with two hidden states --- i.e. `healthy / nominal' and `unhealthy / faulty'. The fault detection is performed by first clustering in a multidimensional data space to define normal operating behaviour using a Gaussian-Uniform mixture model. The health status of the system at each data point is then determined by evaluating the posterior probabilities of the hidden states of a hidden Markov model. This allows the temporal relationship between sequential data points to be incorporated into the fault detection scheme. The proposed scheme is robust to noise and requires minimal tuning. A real-world case study is performed based on the detection of transient faults in the variable stator vane actuator of a gas turbine engine to demonstrate the successful application of the scheme. The results are used to demonstrate the generation of simple and easily interpretable analytics that can be used to monitor the evolution of the fault across time