An Integrated Approach to Performance Monitoring and Fault Diagnosis of Nuclear Power Systems

In this dissertation an integrated framework of process performance monitoring and fault diagnosis was developed for nuclear power systems using robust data driven model based methods, which comprises thermal hydraulic simulation, data driven modeling, identification of model uncertainty, and robust residual generator design for fault detection and isolation. In the applications to nuclear power systems, on the one hand, historical data are often not able to characterize the relationships among process variables because operating setpoints may change and thermal fluid components such as steam generators and heat exchangers may experience degradation. On the other hand, first-principle models always have uncertainty and are often too complicated in terms of model structure to design residual generators for fault diagnosis. Therefore, a realistic fault diagnosis method needs to combine the strength of first principle models in modeling a wide range of anticipated operation conditions and the strength of data driven modeling in feature extraction. In the developed robust data driven model-based approach, the changes in operation conditions are simulated using the first principle models and the model uncertainty is extracted from plant operation data such that the fault effects on process variables can be decoupled from model uncertainty and normal operation changes. It was found that the developed robust fault diagnosis method was able to eliminate false alarms due to model uncertainty and deal with changes in operating conditions throughout the lifetime of nuclear power systems. Multiple methods of robust data driven model based fault diagnosis were developed in this dissertation. A complete procedure based on causal graph theory and data reconciliation method was developed to investigate the causal relationships and the quantitative sensitivities among variables so that sensor placement could be optimized for fault diagnosis in the design phase. Reconstruction based Principal Component Analysis (PCA) approach was applied to deal with both simple faults and complex faults for steady state diagnosis in the context of operation scheduling and maintenance management. A robust PCA model-based method was developed to distinguish the differences between fault effects and model uncertainties. In order to improve the sensitivity of fault detection, a hybrid PCA model based approach was developed to incorporate system knowledge into data driven modeling. Subspace identification was proposed to extract state space models from thermal hydraulic simulations and a robust dynamic residual generator design algorithm was developed for fault diagnosis for the purpose of fault tolerant control and extension to reactor startup and load following operation conditions. The developed robust dynamic residual generator design algorithm is unique in that explicit identification of model uncertainty is not necessary. Finally, it was demonstrated that the developed new methods for the IRIS Helical Coil Steam Generator (HCSG) system. A simulation model was first developed for this system. It was revealed through steady state simulation that the primary coolant temperature profile could be used to indicate the water inventory inside the HCSG tubes. The performance monitoring and fault diagnosis module was then developed to monitor sensor faults, flow distribution abnormality, and heat performance degradation for both steady state and dynamic operation conditions. This dissertation bridges the gap between the theoretical research on computational intelligence and the engineering design in performance monitoring and fault diagnosis for nuclear power systems. The new algorithms have the potential of being integrated into the Generation III and Generation IV nuclear reactor I&C design after they are tested on current nuclear power plants or Generation IV prototype reactors

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

Profitability, reliability and condition based monitoring of LNG floating platforms: a review

The efficiency and profitability of Floating, Production, Storage and Offloading platform (FPSO) terminals depends on various factors such as LNG liquefaction process type, system reliability and maintenance approach. This review is organized along the following research questions: (i) what are the economic benefit of FPSO and how does the liquefaction process type affect its profitability profile?, (ii) how to improve the reliability of the liquefaction system as key section? and finally (iii) what are the major CBM techniques applied on FPSO. The paper concluded the literature and identified the research shortcomings in order to improve profitability, efficiency and availability of FPSOs

SUSTAINABLE LIFETIME VALUE CREATION THROUGH INNOVATIVE PRODUCT DESIGN: A PRODUCT ASSURANCE MODEL

In the field of product development, many organizations struggle to create a value proposition that can overcome the headwinds of technology change, regulatory requirements, and intense competition, in an effort to satisfy the long-term goals of sustainability. Today, organizations are realizing that they have lost portfolio value due to poor reliability, early product retirement, and abandoned design platforms. Beyond Lean and Green Manufacturing, shareholder value can be enhanced by taking a broader perspective, and integrating sustainability innovation elements into product designs in order to improve the delivery process and extend the life of product platforms. This research is divided into two parts that lead to closing the loop towards Sustainable Value Creation in product development. The first section presents a framework for achieving Sustainable Lifetime Value through a toolset that bridges the gap between financial success and sustainable product design. Focus is placed on the analysis of the sustainable value proposition between producers, consumers, society, and the environment and the half-life of product platforms. The Half-Life Return Model is presented, designed to provide feedback to producers in the pursuit of improving the return on investment for the primary stakeholders. The second part applies the driving aspects of the framework with the development of an Adaptive Genetic Search Algorithm. The algorithm is designed to improve fault detection and mitigation during the product delivery process. A computer simulation is used to study the effectiveness of primary aspects introduced in the search algorithm, in order to attempt to improve the reliability growth of the system during the development life-cycle. The results of the analysis draw attention to the sensitivity of the driving aspects identified in the product development lifecycle, which affect the long term goals of sustainable product development. With the use of the techniques identified in this research, cost effective test case generation can be improved without a major degradation in the diversity of the search patterns required to insure a high level of fault detection. This in turn can lead to improvements in the driving aspects of the Half-Life Return Model, and ultimately the goal of designing sustainable products and processes

Development of a Data Driven Multiple Observer and Causal Graph Approach for Fault Diagnosis of Nuclear Power Plant Sensors and Field Devices

Data driven multiple observer and causal graph approach to fault detection and isolation is developed for nuclear power plant sensors and actuators. It can be integrated into the advanced instrumentation and control system for the next generation nuclear power plants. The developed approach is based on analytical redundancy principle of fault diagnosis. Some analytical models are built to generate the residuals between measured values and expected values. Any significant residuals are used for fault detection and the residual patterns are analyzed for fault isolation. Advanced data driven modeling methods such as Principal Component Analysis and Adaptive Network Fuzzy Inference System are used to achieve on-line accurate and consistent models. As compared with most current data-driven modeling, it is emphasized that the best choice of model structure should be obtained from physical study on a system. Multiple observer approach realizes strong fault isolation through designing appropriate residual structures. Even if one of the residuals is corrupted, the approach is able to indicate an unknown fault instead of a misleading fault. Multiple observers are designed through making full use of the redundant relationships implied in a process when predicting one variable. Data-driven causal graph is developed as a generic approach to fault diagnosis for nuclear power plants where limited fault information is available. It has the potential of combining the reasoning capability of qualitative diagnostic method and the strength of quantitative diagnostic method in fault resolution. A data-driven causal graph consists of individual nodes representing plant variables connected with adaptive quantitative models. With the causal graph, fault detection is fulfilled by monitoring the residual of each model. Fault isolation is achieved by testing the possible assumptions involved in each model. Conservatism is implied in the approach since a faulty sensor or a fault actuator signal is isolated only when their reconstructions can fully explain all the abnormal behavior of the system. The developed approaches have been applied to nuclear steam generator system of a pressurized water reactor and a simulation code has been developed to show its performance. The results show that both single and dual sensor faults and actuator faults can be detected and isolated correctly independent of fault magnitudes and initial power level during early fault transient

FAULT DIAGNOSIS TOOLS IN MULTIVARIATE STATISTICAL PROCESS AND QUALITY CONTROL

[EN] An accurate fault diagnosis of both, faults sensors and real process faults have become more and more important for process monitoring (minimize downtime, increase safety of plant operation and reduce the manufacturing cost). Quick and correct fault diagnosis is required in order to put back on track our processes or products before safety or quality can be compromised. In the study and comparison of the fault diagnosis methodologies, this thesis distinguishes between two different scenarios, methods for multivariate statistical quality control (MSQC) and methods for latent-based multivariate statistical process control: (Lb-MSPC). In the first part of the thesis the state of the art on fault diagnosis and identification (FDI) is introduced. The second part of the thesis is devoted to the fault diagnosis in multivariate statistical quality control (MSQC). The rationale of the most extended methods for fault diagnosis in supervised scenarios, the requirements for their implementation, their strong points and their drawbacks and relationships are discussed. The performance of the methods is compared using different performance indices in two different process data sets and simulations. New variants and methods to improve the diagnosis performance in MSQC are also proposed. The third part of the thesis is devoted to the fault diagnosis in latent-based multivariate statistical process control (Lb-MSPC). The rationale of the most extended methods for fault diagnosis in supervised Lb-MSPC is described and one of our proposals, the Fingerprints contribution plots (FCP) is introduced. Finally the thesis presents and compare the performance results of these diagnosis methods in Lb-MSPC. The diagnosis results in two process data sets are compared using a new strategy based in the use of the overall sensitivity and specificity[ES] La realización de un diagnóstico preciso de los fallos, tanto si se trata de fallos de sensores como si se trata de fallos de procesos, ha llegado a ser algo de vital importancia en la monitorización de procesos (reduce las paradas de planta, incrementa la seguridad de la operación en planta y reduce los costes de producción). Se requieren diagnósticos rápidos y correctos si se quiere poder recuperar los procesos o productos antes de que la seguridad o la calidad de los mismos se pueda ver comprometida. En el estudio de las diferentes metodologías para el diagnóstico de fallos esta tesis distingue dos escenarios diferentes, métodos para el control de estadístico multivariante de la calidad (MSQC) y métodos para el control estadístico de procesos basados en el uso de variables latentes (Lb-MSPC). En la primera parte de esta tesis se introduce el estado del arte sobre el diagnóstico e identificación de fallos (FDI). La segunda parte de la tesis está centrada en el estudio del diagnóstico de fallos en control estadístico multivariante de la calidad. Se describen los fundamentos de los métodos más extendidos para el diagnóstico en escenarios supervisados, sus requerimientos para su implementación sus puntos fuertes y débiles y sus posibles relaciones. Los resultados de diagnóstico de los métodos es comparado usando diferentes índices sobre los datos procedentes de dos procesos reales y de diferentes simulaciones. En la tesis se proponen nuevas variantes que tratan de mejorar los resultados obtenidos en MSQC. La tercera parte de la tesis está dedicada al diagnóstico de fallos en control estadístico multivariante de procesos basados en el uso de modelos de variables latentes (Lb-MSPC). Se describe los fundamentos de los métodos mas extendidos en el diagnóstico de fallos en Lb-MSPC supervisado y se introduce una de nuestras propuestas, el fingerprint contribution plot (FCP). Finalmente la tesis presenta y compara los resultados de diagnóstico de los métodos propuestos en Lb-MSPC. Los resultados son comparados sobre los datos de dos procesos usando una nueva estrategia basada en el uso de la sensitividad y especificidad promedia.[CA] La realització d'un diagnòstic precís de les fallades, tant si es tracta de fallades de sensors com si es tracta de fallades de processos, ha arribat a ser de vital importància en la monitorització de processos (reduïx les parades de planta, incrementa la seguretat de l'operació en planta i reduïx els costos de producció) . Es requerixen diagnòstics ràpids i correctes si es vol poder recuperar els processos o productes abans de que la seguretat o la qualitat dels mateixos es puga veure compromesa. En l'estudi de les diferents metodologies per al diagnòstic de fallades esta tesi distingix dos escenaris diferents, mètodes per al control estadístic multivariant de la qualitat (MSQC) i l mètodes per al control estadístic de processos basats en l'ús de variables latents (Lb-MSPC). En la primera part d'esta tesi s'introduïx l'estat de l'art sobre el diagnòstic i identificació de fallades (FDI). La segona part de la tesi està centrada en l'estudi del diagnòstic de fallades en control estadístic multivariant de la qualitat. Es descriuen els fonaments dels mètodes més estesos per al diagnòstic en escenaris supervisats, els seus requeriments per a la seua implementació els seus punts forts i febles i les seues possibles relacions. Els resultats de diagnòstic dels mètodes és comparat utilitzant diferents índexs sobre les dades procedents de dos processos reals i de diferents simulacions. En la tesi es proposen noves variants que tracten de millorar els resultats obtinguts en MSQC. La tercera part de la tesi està dedicada al diagnòstic de fallades en control estadístic multivariant de processos basat en l'ús de models de variables latents (Lb-MSPC). Es descriu els fonaments dels mètodes més estesos en el diagnòstic de fallades en MSPC supervisat i s'introdueix una nova proposta, el fingerprint contribution plot (FCP). Finalment la tesi presenta i compara els resultats de diagnòstic dels mètodes proposats en MSPC. Els resultats són comparats sobre les dades de dos processos utilitzant una nova estratègia basada en l'ús de la sensibilitat i especificitat mitjana.Vidal Puig, S. (2016). FAULT DIAGNOSIS TOOLS IN MULTIVARIATE STATISTICAL PROCESS AND QUALITY CONTROL [Tesis doctoral no publicada]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/61292TESI

Wind Turbine Active Fault Tolerant Control Based on Backstepping Active Disturbance Rejection Control and a Neurofuzzy Detector

© 2023 The Author(s). Licensee MDPI, Basel, Switzerland. This is an open access article distributed under the terms of the Creative Commons Attribution License (CC BY), https://creativecommons.org/licenses/by/4.0/Wind energy conversion systems have become an important part of renewable energy history due to their accessibility and cost-effectiveness. Offshore wind farms are seen as the future of wind energy, but they can be very expensive to maintain if faults occur. To achieve a reliable and consistent performance, modern wind turbines require advanced fault detection and diagnosis methods. The current research introduces a proposed active fault-tolerant control (AFTC) system that uses backstepping active disturbance rejection theory (BADRC) and an adaptive neurofuzzy system (ANFIS) detector in combination with principal component analysis (PCA) to compensate for system disturbances and maintain performance even when a generator actuator fault occurs. The simulation outcomes demonstrate that the suggested method successfully addresses the actuator generator torque failure problem by isolating the faulty actuator, providing a reliable and robust solution to prevent further damage. The neurofuzzy detector demonstrates outstanding performance in detecting false data in torque, achieving a precision of 90.20% for real data and 100%, for false data. With a recall of 100%, no false negatives were observed. The overall accuracy of 95.10% highlights the detector’s ability to reliably classify data as true or false. These findings underscore the robustness of the detector in detecting false data, ensuring the accuracy and reliability of the application presented. Overall, the study concludes that BADRC and ANFIS detection and isolation can improve the reliability of offshore wind farms and address the issue of actuator generator torque failure.Peer reviewe

Model based fault diagnosis and prognosis of nonlinear systems

Rapid technological advances have led to more and more complex industrial systems with significantly higher risk of failures. Therefore, in this dissertation, a model-based fault diagnosis and prognosis framework has been developed for fast and reliable detection of faults and prediction of failures in nonlinear systems. In the first paper, a unified model-based fault diagnosis scheme capable of detecting both additive system faults and multiplicative actuator faults, as well as approximating the fault dynamics, performing fault type determination and time-to-failure determination, is designed. Stability of the observer and online approximator is guaranteed via an adaptive update law. Since outliers can degrade the performance of fault diagnostics, the second paper introduces an online neural network (NN) based outlier identification and removal scheme which is then combined with a fault detection scheme to enhance its performance. Outliers are detected based on the estimation error and a novel tuning law prevents the NN weights from being affected by outliers. In the third paper, in contrast to papers I and II, fault diagnosis of large-scale interconnected systems is investigated. A decentralized fault prognosis scheme is developed for such systems by using a network of local fault detectors (LFD) where each LFD only requires the local measurements. The online approximators in each LFD learn the unknown interconnection functions and the fault dynamics. Derivation of robust detection thresholds and detectability conditions are also included. The fourth paper extends the decentralized fault detection from paper III and develops an accommodation scheme for nonlinear continuous-time systems. By using both detection and accommodation online approximators, the control inputs are adjusted in order to minimize the fault effects. Finally in the fifth paper, the model-based fault diagnosis of distributed parameter systems (DPS) with parabolic PDE representation in continuous-time is discussed where a PDE-based observer is designed to perform fault detection as well as estimating the unavailable system states. An adaptive online approximator is incorporated in the observer to identify unknown fault parameters. Adaptive update law guarantees the convergence of estimations and allows determination of remaining useful life --Abstract, page iv