Alarm flood reduction using multiple data sources

The introduction of distributed control systems in the process industry has increased the number of alarms per operator exponentially. Modern plants present a high level of interconnectivity due to steam recirculation, heat integration and the complex control systems installed in the plant. When there is a disturbance in the plant it spreads through its material, energy and information connections affecting the process variables on the path. The alarms associated to these process variables are triggered. The alarm messages may overload the operator in the control room, who will not be able to properly investigate each one of these alarms. This undesired situation is called an “alarm flood”. In such situations the operator might not be able to keep the plant within safe operation. The aim of this thesis is to reduce alarm flood periods in process plants. Consequential alarms coming from the same process abnormality are isolated and a causal alarm suggestion is given. The causal alarm in an alarm flood is the alarm associated to the asset originating the disturbance that caused the flood. Multiple information sources are used: an alarm log containing all past alarms messages, process data and a topology model of the plant. The alarm flood reduction is achieved with a combination of alarm log analysis, process data root-cause analysis and connectivity analysis. The research findings are implemented in a software tool that guides the user through the different steps of the method. Finally the applicability of the method is proved with an industrial case study

Process Performance Analysis in Large-Scale Systems Integrating Different Sources of Information

Process auditing using historical data can identify causes for poor performance and reveal opportunities to improve process operation. To date, the data used has been limited to process measurements; however other sources hold complementary information about the process behavior. This paper proposes a new approach to root-cause diagnosis, which also takes advantage of the information in utility, mechanical and electrical data, alarms and diagrams. Its benefit is demonstrated in an industrial case study, by tackling an important challenge in root-cause analysis: large-scale systems. This paper also defines specifications for a semi-automated tool to implement the proposed approach. © 2012 IFAC

DaaS: Dew Computing as a Service for Intelligent Intrusion Detection in Edge-of-Things Ecosystem

Edge of Things (EoT) enables the seamless transfer of services, storage, and data processing from the cloud layer to edge devices in a large-scale distributed Internet of Things (IoT) ecosystems (e.g., Industrial systems). This transition raises the privacy and security concerns in the EoT paradigm distributed at different layers. Intrusion detection systems (IDSs) are implemented in EoT ecosystems to protect the underlying resources from attackers. However, the current IDSs are not intelligent enough to control the false alarms, which significantly lower the reliability and add to the analysis burden on the IDSs. In this article, we present a Dew Computing as a Service (DaaS) for intelligent intrusion detection in EoT ecosystems. In DaaS, a deep learning-based classifier is used to design an intelligent alarm filtration mechanism. In this mechanism, the filtration accuracy is improved (or sustained) by using deep belief networks. In the past, the cloud-based techniques have been applied for offloading the EoT tasks, which increases the middle layer burden and raises the communication delay. Here, we introduce the dew computing features that are used to design the smart false alarm reduction system. DaaS, when experimented in a simulated environment, reflects lower response time to process the data in the EoT ecosystem. The revamped DBN model achieved the classification accuracy up to 95%. Moreover, it depicts a 60% improvement in the latency and 35% workload reduction of the cloud servers as compared to edge IDS

Alert Diagnostic System: SDA

Currently, there is a trend in reduction of the number of industrial plant operators. The challenges are mainly during emergency situations: how to support operator time management without increasing operational risks? SDA focuses on this area and aims to increase operator situational awareness (ability to perceive, understand and predict the future behavior of a process) through new technological paradigms, such as Expert System and Ecological Human Machine Interface (HMI) in order to provide operational support, maintenance and optimization of refining, exploration and system of production of oil and gas plants. In SDA, the most critical alerts are shown by priority, along with decision trees, trend charts and variable comparison charts. SDA aims to assist control room operators in solving a critical problem in the oil industry, that is the loss of safety function, associated with alarms, during alarm flood. The SDA results of the SDA are presented through its implementation in Sulfur Recovery Units—URE, in the state of Rio de Janeiro, in Brazil

Thread Quality Control in High-Speed Tapping Cycles

Thread quality control is becoming a widespread necessity in manufacturing to guarantee the geometry of the resulting screws on the workpiece due to the high industrial costs. Besides, the industrial inspection is manual provoking high rates of manufacturing delays. Therefore, the aim of this paper consists of developing a statistical quality control approach acquiring the data (torque signal) coming from the spindle drive for assessing thread quality using different coatings. The system shows a red light when the tap wear is critical before machining in unacceptable screw threads. Therefore, the application could reduce these high industrial costs because it can work self-governance.This research was funded by the vice‐counseling of technology, innovation and competitiveness of the Basque Government grant agreements IT‐2005/00201, ZL‐2019/00720 (HARDCRAFT project) and KK‐2019/00004 (PROCODA project)

A log mining approach for process monitoring in SCADA

SCADA (Supervisory Control and Data Acquisition) systems are used for controlling and monitoring industrial processes. We propose a methodology to systematically identify potential process-related threats in SCADA. Process-related threats take place when an attacker gains user access rights and performs actions, which look legitimate, but which are intended to disrupt the SCADA process. To detect such threats, we propose a semi-automated approach of log processing. We conduct experiments on a real-life water treatment facility. A preliminary case study suggests that our approach is effective in detecting anomalous events that might alter the regular process workflow

Risk analysis and reliability of the GERDA Experiment extraction and ventilation plant at Gran Sasso mountain underground laboratory of Italian National Institute for Nuclear Physics

The aim of this study is the risk analysis evaluation about argon release from the GERDA experiment in the Gran Sasso underground National Laboratories (LNGS) of the Italian National Institute for Nuclear Physics (INFN). The GERDA apparatus, located in Hall A of the LNGS, is a facility with germanium detectors located in a wide tank filled with about 70 m3 of cold liquefied argon. This cryo-tank sits in another water-filled tank (700 m3) at atmospheric pressure. In such cryogenic processes, the main cause of an accidental scenario is lacking insulation of the cryo-tank. A preliminary HazOp analysis has been carried out on the whole system. The risk assessment identified two possible top-events: explosion due to a Rapid Phase Transition - RPT and argon runaway evaporation. Risk analysis highlighted a higher probability of occurrence of the latter top event. To avoid emission in Hall A, the HazOp, Fault Tree and Event tree analyses of the cryogenic gas extraction and ventilation plant have been made. The failures related to the ventilation system are the main cause responsible for the occurrence. To improve the system reliability some corrective actions were proposed: the use of UPS and the upgrade of damper opening devices. Furthermore, the Human Reliability Analysis identified some operating and management improvements: action procedure optimization, alert warnings and staff training. The proposed model integrates the existing analysis techniques by applying the results to an atypical work environment and there are useful suggestions for improving the system reliability

Deep Predictive Coding Neural Network for RF Anomaly Detection in Wireless Networks

Intrusion detection has become one of the most critical tasks in a wireless network to prevent service outages that can take long to fix. The sheer variety of anomalous events necessitates adopting cognitive anomaly detection methods instead of the traditional signature-based detection techniques. This paper proposes an anomaly detection methodology for wireless systems that is based on monitoring and analyzing radio frequency (RF) spectrum activities. Our detection technique leverages an existing solution for the video prediction problem, and uses it on image sequences generated from monitoring the wireless spectrum. The deep predictive coding network is trained with images corresponding to the normal behavior of the system, and whenever there is an anomaly, its detection is triggered by the deviation between the actual and predicted behavior. For our analysis, we use the images generated from the time-frequency spectrograms and spectral correlation functions of the received RF signal. We test our technique on a dataset which contains anomalies such as jamming, chirping of transmitters, spectrum hijacking, and node failure, and evaluate its performance using standard classifier metrics: detection ratio, and false alarm rate. Simulation results demonstrate that the proposed methodology effectively detects many unforeseen anomalous events in real time. We discuss the applications, which encompass industrial IoT, autonomous vehicle control and mission-critical communications services.Comment: 7 pages, 7 figures, Communications Workshop ICC'1