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

Goal-Oriented Mutation Testing with Focal Methods

Mutation testing is the state-of-the-art technique for assessing the fault-detection capacity of a test suite. Unfortunately, mutation testing consumes enormous computing resources because it runs the whole test suite for each and every injected mutant. In this paper we explore fine-grained traceability links at method level (named focal methods), to reduce the execution time of mutation testing and to verify the quality of the test cases for each individual method, instead of the usually verified overall test suite quality. Validation of our approach on the open source Apache Ant project shows a speed-up of 573.5x for the mutants located in focal methods with a quality score of 80%.Comment: A-TEST 201

Optimal Sensor Selection for Health Monitoring Systems

Sensor data are the basis for performance and health assessment of most complex systems. Careful selection and implementation of sensors is critical to enable high fidelity system health assessment. A model-based procedure that systematically selects an optimal sensor suite for overall health assessment of a designated host system is described. This procedure, termed the Systematic Sensor Selection Strategy (S4), was developed at NASA John H. Glenn Research Center in order to enhance design phase planning and preparations for in-space propulsion health management systems (HMS). Information and capabilities required to utilize the S4 approach in support of design phase development of robust health diagnostics are outlined. A merit metric that quantifies diagnostic performance and overall risk reduction potential of individual sensor suites is introduced. The conceptual foundation for this merit metric is presented and the algorithmic organization of the S4 optimization process is described. Representative results from S4 analyses of a boost stage rocket engine previously under development as part of NASA's Next Generation Launch Technology (NGLT) program are presented

Sensor Selection and Optimization for Health Assessment of Aerospace Systems

Aerospace systems are developed similarly to other large-scale systems through a series of reviews, where designs are modified as system requirements are refined. For space-based systems few are built and placed into service. These research vehicles have limited historical experience to draw from and formidable reliability and safety requirements, due to the remote and severe environment of space. Aeronautical systems have similar reliability and safety requirements, and while these systems may have historical information to access, commercial and military systems require longevity under a range of operational conditions and applied loads. Historically, the design of aerospace systems, particularly the selection of sensors, is based on the requirements for control and performance rather than on health assessment needs. Furthermore, the safety and reliability requirements are met through sensor suite augmentation in an ad hoc, heuristic manner, rather than any systematic approach. A review of the current sensor selection practice within and outside of the aerospace community was conducted and a sensor selection architecture is proposed that will provide a justifiable, dependable sensor suite to address system health assessment requirements

On the Effectiveness of Contracts as Test Oracles in the Detection and Diagnosis of Faults in Concurrent Object-Oriented Software

Design by Contract (DbC) is a software development methodology that focuses on clearly defining the interfaces between components to produce better quality object-oriented software. The idea behind DbC is that a method defines a contract stating the requirements a client needs to fulfill to use it, the precondition, and the properties it ensures after its execution, the postcondition. Though there exists ample support for DbC for sequential programs, applying DbC to concurrent programs presents several challenges. Using Java as the target programming language, this paper tackles such challenges by augmenting the Java Modelling Language (JML) and modifying the JML compiler to generate Runtime Assertion Checking (RAC) code to support DbC in concurrent programs. We applied our solution in a carefully designed case study on a highly concurrent industrial software system from the telecommunications domain to assess the effectiveness of contracts as test oracles in detecting and diagnosing functional faults in concurrent software. Based on these results, clear and objective requirements are defined for contracts to be effective test oracles for concurrent programs whilst balancing the effort to design them. Main results include that contracts of a realistic level of completeness and complexity can detect around 76% of faults and reduce the diagnosis effort for such faults by at least ten times. We, therefore, show that DbC can not only be applied to concurrent software but can also be a valua

An Empirical Evaluation of the Effectiveness of JML Assertions as Test Oracles

Test oracles remain one of the least understood aspects of the modern testing process. An oracle is a mechanism used by software testers and software engineers for determining whether a test has passed or failed. One widely-supported approach to oracles is the use of runtime assertion checking during the testing activity. Method invariants,pre- and postconditions help detect bugs during runtime. While assertions are supported by virtually all programming environments, are used widely in practice, and are often assumed to be effective as test oracles, there are few empirical studies of their efficacy in this role. In this thesis, we present the results of an experiment we conducted to help understand this question. To do this, we studied seven of the core Java classes that had been annotated by others with assertions in the Java Modeling Language, used the muJava mutation analysis tool to create mutant implementations of these classes, exercised them with input-only (i.e., no oracle) test suites that achieve branch coverage, and used a machine learning tool, Weka, to determine which annotations were effective at ``killing\u27\u27 these mutants. We also evaluate how effective the ``null oracle\u27\u27 (in our case, the Java runtime system) is at catching these bugs. The results of our study are interesting, and help provide software engineers with insight into situations in which assertions can be relied upon to find bugs, and situations in which assertions may need to be augmented with other approaches to test oracles

Spectrum-based Fault Localization Techniques Application on Multiple-Fault Programs: A Review

Software fault localization is one of the most tedious and costly activities in program debugging in the endeavor to identify faults locations in a software program. In this paper, the studies that used spectrum-based fault localization (SBFL) techniques that makes use of different multiple fault localization debugging methods such as one-bug-at-a-time (OBA) debugging, parallel debugging, and simultaneous debugging in localizing multiple faults are classified and critically analyzed in order to extensively discuss the current research trends, issues, and challenges in this field of study. The outcome strongly shows that there is a high utilization of OBA debugging method, poor fault isolation accuracy, and dominant use of artificial faults that limit the existing techniques applicability in the software industry