Methods and Systems for Fault Diagnosis in Nuclear Power Plants

This research mainly deals with fault diagnosis in nuclear power plants (NPP), based on a framework that integrates contributions from fault scope identification, optimal sensor placement, sensor validation, equipment condition monitoring, and diagnostic reasoning based on pattern analysis. The research has a particular focus on applications where data collected from the existing SCADA (supervisory, control, and data acquisition) system is not sufficient for the fault diagnosis system. Specifically, the following methods and systems are developed. A sensor placement model is developed to guide optimal placement of sensors in NPPs. The model includes 1) a method to extract a quantitative fault-sensor incidence matrix for a system; 2) a fault diagnosability criterion based on the degree of singularities of the incidence matrix; and 3) procedures to place additional sensors to meet the diagnosability criterion. Usefulness of the proposed method is demonstrated on a nuclear power plant process control test facility (NPCTF). Experimental results show that three pairs of undiagnosable faults can be effectively distinguished with three additional sensors selected by the proposed model. A wireless sensor network (WSN) is designed and a prototype is implemented on the NPCTF. WSN is an effective tool to collect data for fault diagnosis, especially for systems where additional measurements are needed. The WSN has distributed data processing and information fusion for fault diagnosis. Experimental results on the NPCTF show that the WSN system can be used to diagnose all six fault scenarios considered for the system. A fault diagnosis method based on semi-supervised pattern classification is developed which requires significantly fewer training data than is typically required in existing fault diagnosis models. It is a promising tool for applications in NPPs, where it is usually difficult to obtain training data under fault conditions for a conventional fault diagnosis model. The proposed method has successfully diagnosed nine types of faults physically simulated on the NPCTF. For equipment condition monitoring, a modified S-transform (MST) algorithm is developed by using shaping functions, particularly sigmoid functions, to modify the window width of the existing standard S-transform. The MST can achieve superior time-frequency resolution for applications that involves non-stationary multi-modal signals, where classical methods may fail. Effectiveness of the proposed algorithm is demonstrated using a vibration test system as well as applications to detect a collapsed pipe support in the NPCTF. The experimental results show that by observing changes in time-frequency characteristics of vibration signals, one can effectively detect faults occurred in components of an industrial system. To ensure that a fault diagnosis system does not suffer from erroneous data, a fault detection and isolation (FDI) method based on kernel principal component analysis (KPCA) is extended for sensor validations, where sensor faults are detected and isolated from the reconstruction errors of a KPCA model. The method is validated using measurement data from a physical NPP. The NPCTF is designed and constructed in this research for experimental validations of fault diagnosis methods and systems. Faults can be physically simulated on the NPCTF. In addition, the NPCTF is designed to support systems based on different instrumentation and control technologies such as WSN and distributed control systems. The NPCTF has been successfully utilized to validate the algorithms and WSN system developed in this research. In a real world application, it is seldom the case that one single fault diagnostic scheme can meet all the requirements of a fault diagnostic system in a nuclear power. In fact, the values and performance of the diagnosis system can potentially be enhanced if some of the methods developed in this thesis can be integrated into a suite of diagnostic tools. In such an integrated system, WSN nodes can be used to collect additional data deemed necessary by sensor placement models. These data can be integrated with those from existing SCADA systems for more comprehensive fault diagnosis. An online performance monitoring system monitors the conditions of the equipment and provides key information for the tasks of condition-based maintenance. When a fault is detected, the measured data are subsequently acquired and analyzed by pattern classification models to identify the nature of the fault. By analyzing the symptoms of the fault, root causes of the fault can eventually be identified

Tools and Algorithms for the Construction and Analysis of Systems

This open access book constitutes the proceedings of the 28th International Conference on Tools and Algorithms for the Construction and Analysis of Systems, TACAS 2022, which was held during April 2-7, 2022, in Munich, Germany, as part of the European Joint Conferences on Theory and Practice of Software, ETAPS 2022. The 46 full papers and 4 short papers presented in this volume were carefully reviewed and selected from 159 submissions. The proceedings also contain 16 tool papers of the affiliated competition SV-Comp and 1 paper consisting of the competition report. TACAS is a forum for researchers, developers, and users interested in rigorously based tools and algorithms for the construction and analysis of systems. The conference aims to bridge the gaps between different communities with this common interest and to support them in their quest to improve the utility, reliability, exibility, and efficiency of tools and algorithms for building computer-controlled systems

Design Disjunction for Resilient Reconfigurable Hardware

Contemporary reconfigurable hardware devices have the capability to achieve high performance, power efficiency, and adaptability required to meet a wide range of design goals. With scaling challenges facing current complementary metal oxide semiconductor (CMOS), new concepts and methodologies supporting efficient adaptation to handle reliability issues are becoming increasingly prominent. Reconfigurable hardware and their ability to realize self-organization features are expected to play a key role in designing future dependable hardware architectures. However, the exponential increase in density and complexity of current commercial SRAM-based field-programmable gate arrays (FPGAs) has escalated the overhead associated with dynamic runtime design adaptation. Traditionally, static modular redundancy techniques are considered to surmount this limitation; however, they can incur substantial overheads in both area and power requirements. To achieve a better trade-off among performance, area, power, and reliability, this research proposes design-time approaches that enable fine selection of redundancy level based on target reliability goals and autonomous adaptation to runtime demands. To achieve this goal, three studies were conducted: First, a graph and set theoretic approach, named Hypergraph-Cover Diversity (HCD), is introduced as a preemptive design technique to shift the dominant costs of resiliency to design-time. In particular, union-free hypergraphs are exploited to partition the reconfigurable resources pool into highly separable subsets of resources, each of which can be utilized by the same synthesized application netlist. The diverse implementations provide reconfiguration-based resilience throughout the system lifetime while avoiding the significant overheads associated with runtime placement and routing phases. Evaluation on a Motion-JPEG image compression core using a Xilinx 7-series-based FPGA hardware platform has demonstrated the potential of the proposed FT method to achieve 37.5% area saving and up to 66% reduction in power consumption compared to the frequently-used TMR scheme while providing superior fault tolerance. Second, Design Disjunction based on non-adaptive group testing is developed to realize a low-overhead fault tolerant system capable of handling self-testing and self-recovery using runtime partial reconfiguration. Reconfiguration is guided by resource grouping procedures which employ non-linear measurements given by the constructive property of f-disjunctness to extend runtime resilience to a large fault space and realize a favorable range of tradeoffs. Disjunct designs are created using the mosaic convergence algorithm developed such that at least one configuration in the library evades any occurrence of up to d resource faults, where d is lower-bounded by f. Experimental results for a set of MCNC and ISCAS benchmarks have demonstrated f-diagnosability at the individual slice level with average isolation resolution of 96.4% (94.4%) for f=1 (f=2) while incurring an average critical path delay impact of only 1.49% and area cost roughly comparable to conventional 2-MR approaches. Finally, the proposed Design Disjunction method is evaluated as a design-time method to improve timing yield in the presence of large random within-die (WID) process variations for application with a moderately high production capacity

Tools and Algorithms for the Construction and Analysis of Systems

This open access book constitutes the proceedings of the 28th International Conference on Tools and Algorithms for the Construction and Analysis of Systems, TACAS 2022, which was held during April 2-7, 2022, in Munich, Germany, as part of the European Joint Conferences on Theory and Practice of Software, ETAPS 2022. The 46 full papers and 4 short papers presented in this volume were carefully reviewed and selected from 159 submissions. The proceedings also contain 16 tool papers of the affiliated competition SV-Comp and 1 paper consisting of the competition report. TACAS is a forum for researchers, developers, and users interested in rigorously based tools and algorithms for the construction and analysis of systems. The conference aims to bridge the gaps between different communities with this common interest and to support them in their quest to improve the utility, reliability, exibility, and efficiency of tools and algorithms for building computer-controlled systems

Smart Manufacturing

This book is a collection of 11 articles that are published in the corresponding Machines Special Issue “Smart Manufacturing”. It represents the quality, breadth and depth of the most updated study in smart manufacturing (SM); in particular, digital technologies are deployed to enhance system smartness by (1) empowering physical resources in production, (2) utilizing virtual and dynamic assets over the Internet to expand system capabilities, (3) supporting data-driven decision-making activities at various domains and levels of businesses, or (4) reconfiguring systems to adapt to changes and uncertainties. System smartness can be evaluated by one or a combination of performance metrics such as degree of automation, cost-effectiveness, leanness, robustness, flexibility, adaptability, sustainability, and resilience. This book features, firstly, the concepts digital triad (DT-II) and Internet of digital triad things (IoDTT), proposed to deal with the complexity, dynamics, and scalability of complex systems simultaneously. This book also features a comprehensive survey of the applications of digital technologies in space instruments; a systematic literature search method is used to investigate the impact of product design and innovation on the development of space instruments. In addition, the survey provides important information and critical considerations for using cutting edge digital technologies in designing and manufacturing space instruments

Fault Diagnosis Algorithms for Wireless Sensor Networks

The sensor nodes in wireless sensor networks (WSNs) are deployed in unattended and hostile environments. The ill-disposed environment affects the monitoring infrastructure that includes the sensor nodes and the links. In addition, node failures and environmental hazards cause frequent topology change, communication failure, and network partition. This in turn adds a new dimension to the fragility of the WSN topology. Such perturbations are far more common in WSNs than those found in conventional wireless networks. These perturbations demand efficient techniques for discovering disruptive behavior in WSNs. Traditional fault diagnosis techniques devised for wired interconnected networks, and conventional wireless networks are not directly applicable to WSNs due to its specific requirements and limitations. System-level diagnosis is a technique to identify faults in distributed networks such as multiprocessor systems, wired interconnected networks, and conventional wireless networks. Recently, this has been applied on ad hoc networks and WSNs. This is performed by deduction, based on information in the form of results of tests applied to the sensor nodes. Neighbor coordination-based system-level diagnosis is a variation of this method, which exploits the spatio-temporal correlation between sensor measurements. In this thesis, we present a new approach to diagnose faulty sensor nodes in a WSN, which works in conjunction with the underlying clustering protocol and exploits spatio-temporal correlation between sensor measurements. An advantage of this method is that the diagnostic operation constitutes real work performed by the system, rather than a specialized diagnostic task. In this way, the normal operation of the network can be used for the diagnosis and resulting less time and message overhead. In this thesis, we have devised and evaluated fault diagnosis algorithms for WSNs considering persistence of the faults (transient, intermittent, and permanent), faults in communication channels and in one of the approaches, we attempt to solve the issue of node mobility in diagnosis. A cluster based distributed fault diagnosis (CDFD) algorithm is proposed where the diagnostic local view is obtained by exploiting the spatially correlated sensor measurements. We derived an optimal threshold for effective fault diagnosis in sparse networks. The message complexity of CDFD is O(n) and the number of bits exchanged to diagnose the network are O(n log2 n). The intermittent fault diagnosis is formulated as a multiobjective optimization problem based on the inter-test interval and number of test repetitions required to diagnose the intermittent faults. The two objectives such as detection latency and energy overhead are taken into consideration with a constraint of detection errors. A high level (> 95%) of detection accuracy is achieved while keeping the false alarm rate low (< 1%) for sparse networks. The proposed cluster based distributed intermittent fault diagnosis (CDIFD) algorithm is energy efficient because in CDIFD, diagnostic messages are sent as the output of the routine tasks of the WSNs. A count and threshold-based mechanism is used to discriminate the persistence of faults. The main characteristics of these faults are the amounts of time the fault disappears. We adopt this state-holding time to discriminate transient from intermittent or permanent faults. The proposed cluster based distributed fault diagnosis and discrimination (CDFDD) algorithm is energy efficient due to the improved network lifetime which is greater than 1150 data-gathering rounds with transient fault rates as high as 20%. A mobility aware hierarchal architecture is proposed which is to detect hard and soft faults in dynamic WSN topology assuming random movements of nodes in the WSN. A test pattern that ensures error checking of each functional block of a sensor node is employed to diagnose the network. The proposed mobility aware cluster based distributed fault diagnosis (MCDFD) algorithm assures a better packet delivery ratio (> 80%) in highly dynamic networks with a fault rate as high as 30%. The network lifetime is more than 900 data-gathering rounds in a highly dynamic network with a fault rate as high as 20%

Fault-tolerant software: dependability/performance trade-offs, concurrency and system support

PhD ThesisAs the use of computer systems becomes more and more widespread in applications that demand high levels of dependability, these applications themselves are growing in complexity in a rapid rate, especially in the areas that require concurrent and distributed computing. Such complex systems are very prone to faults and errors. No matter how rigorously fault avoidance and fault removal techniques are applied, software design faults often remain in systems when they are delivered to the customers. In fact, residual software faults are becoming the significant underlying cause of system failures and the lack of dependability. There is tremendous need for systematic techniques for building dependable software, including the fault tolerance techniques that ensure software-based systems to operate dependably even when potential faults are present. However, although there has been a large amount of research in the area of fault-tolerant software, existing techniques are not yet sufficiently mature as a practical engineering discipline for realistic applications. In particular, they are often inadequate when applied to highly concurrent and distributed software. This thesis develops new techniques for building fault-tolerant software, addresses the problem of achieving high levels of dependability in concurrent and distributed object systems, and studies system-level support for implementing dependable software. Two schemes are developed - the t/(n-l)-VP approach is aimed at increasing software reliability and controlling additional complexity, while the SCOP approach presents an adaptive way of dynamically adjusting software reliability and efficiency aspects. As a more general framework for constructing dependable concurrent and distributed software, the Coordinated Atomic (CA) Action scheme is examined thoroughly. Key properties of CA actions are formalized, conceptual model and mechanisms for handling application level exceptions are devised, and object-based diversity techniques are introduced to cope with potential software faults. These three schemes are evaluated analytically and validated by controlled experiments. System-level support is also addressed with a multi-level system architecture. An architectural pattern for implementing fault-tolerant objects is documented in detail to capture existing solutions and our previous experience. An industrial safety-critical application, the Fault-Tolerant Production Cell, is used as a case study to examine most of the concepts and techniques developed in this research.ESPRIT

Safety and Reliability - Safe Societies in a Changing World

The contributions cover a wide range of methodologies and application areas for safety and reliability that contribute to safe societies in a changing world. These methodologies and applications include: - foundations of risk and reliability assessment and management - mathematical methods in reliability and safety - risk assessment - risk management - system reliability - uncertainty analysis - digitalization and big data - prognostics and system health management - occupational safety - accident and incident modeling - maintenance modeling and applications - simulation for safety and reliability analysis - dynamic risk and barrier management - organizational factors and safety culture - human factors and human reliability - resilience engineering - structural reliability - natural hazards - security - economic analysis in risk managemen