Derivation of diagnostic models based on formalized process knowledge

© IFAC.Industrial systems are vulnerable to faults. Early and accurate detection and diagnosis in production systems can minimize down-time, increase the safety of the plant operation, and reduce manufacturing costs. Knowledge- and model-based approaches to automated fault detection and diagnosis have been demonstrated to be suitable for fault cause analysis within a broad range of industrial processes and research case studies. However, the implementation of these methods demands a complex and error-prone development phase, especially due to the extensive efforts required during the derivation of models and their respective validation. In an effort to reduce such modeling complexity, this paper presents a structured causal modeling approach to supporting the derivation of diagnostic models based on formalized process knowledge. The method described herein exploits the Formalized Process Description Guideline VDI/VDE 3682 to establish causal relations among key-process variables, develops an extension of the Signed Digraph model combined with the use of fuzzy set theory to allow more accurate causality descriptions, and proposes a representation of the resulting diagnostic model in CAEX/AutomationML targeting dynamic data access, portability, and seamless information exchange

Practical Model-Based Diagnosis with Qualitative Possibilistic Uncertainty

An approach to fault isolation that exploits vastly incomplete models is presented. It relies on separate descriptions of each component behavior, together with the links between them, which enables focusing of the reasoning to the relevant part of the system. As normal observations do not need explanation, the behavior of the components is limited to anomaly propagation. Diagnostic solutions are disorders (fault modes or abnormal signatures) that are consistent with the observations, as well as abductive explanations. An ordinal representation of uncertainty based on possibility theory provides a simple exception-tolerant description of the component behaviors. We can for instance distinguish between effects that are more or less certainly present (or absent) and effects that are more or less certainly present (or absent) when a given anomaly is present. A realistic example illustrates the benefits of this approach.Comment: Appears in Proceedings of the Eleventh Conference on Uncertainty in Artificial Intelligence (UAI1995

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

Advances in state estimation, diagnosis and control of complex systems

This dissertation intends to provide theoretical and practical contributions on estimation, diagnosis and control of complex systems, especially in the mathematical form of descriptor systems. The research is motivated by real applications, such as water networks and power systems, which require a control system to provide a proper management able to take into account their specific features and operating limits in presence of uncertainties related to their operation and failures from component malfunctions. Such a control system is expected to provide an optimal operation to obtain efficient and reliable performance. State estimation is an essential tool, which can be used not only for fault diagnosis but also for the controller design. To achieve a satisfactory robust performance, set theory is chosen to build a general framework for descriptor systems subject to uncertainties. Under certain assumptions, these uncertainties are propagated and bounded by deterministic sets that can be explicitly characterized at each iteration step. Moreover, set-invariance characterizations for descriptor systems are also of interest to describe the steady performance, which can also be used for active mode detection. For the controller design for complex systems, new developments of economic model predictive control (EMPC) are studied taking into account the case of underlying periodic behaviors. The EMPC controller is designed to be recursively feasible even with sudden changes in the economic cost function and the closed-loop convergence is guaranteed. Besides, a robust technique is plugged into the EMPC controller design to maintain these closed-loop properties in presence of uncertainties. Engineering applications modeled as descriptor systems are presented to illustrate these control strategies. From the real applications, some additional difficulties are solved, such as using a two-layer control strategy to avoid binary variables in real-time optimizations and using nonlinear constraint relaxation to deal with nonlinear algebraic equations in the descriptor model. Furthermore, the fault-tolerant capability is also included in the controller design for descriptor systems by means of the designed virtual actuator and virtual sensor together with an observer-based delayed controller.Esta tesis propone contribuciones de carácter teórico y aplicado para la estimación del estado, el diagnóstico y el control óptimo de sistemas dinámicos complejos en particular, para los sistemas descriptores, incluyendo la capacidad de tolerancia a fallos. La motivación de la tesis proviene de aplicaciones reales, como redes de agua y sistemas de energía, cuya naturaleza crítica requiere necesariamente un sistema de control para una gestión capaz de tener en cuenta sus características específicas y límites operativos en presencia de incertidumbres relacionadas con su funcionamiento, así como fallos de funcionamiento de los componentes. El objetivo es conseguir controladores que mejoren tanto la eficiencia como la fiabilidad de dichos sistemas. La estimación del estado es una herramienta esencial que puede usarse no solo para el diagnóstico de fallos sino también para el diseño del control. Con este fin, se ha decidido utilizar metodologías intervalares, o basadas en conjuntos, para construir un marco general para los sistemas de descriptores sujetos a incertidumbres desconocidas pero acotadas. Estas incertidumbres se propagan y delimitan mediante conjuntos que se pueden caracterizar explícitamente en cada instante. Por otra parte, también se proponen caracterizaciones basadas en conjuntos invariantes para sistemas de descriptores que permiten describir comportamientos estacionarios y resultan útiles para la detección de modos activos. Se estudian también nuevos desarrollos del control predictivo económico basado en modelos (EMPC) para tener en cuenta posibles comportamientos periódicos en la variación de parámetros o en las perturbaciones que afectan a estos sistemas. Además, se demuestra que el control EMPC propuesto garantiza la factibilidad recursiva, incluso frente a cambios repentinos en la función de coste económico y se garantiza la convergencia en lazo cerrado. Por otra parte, se utilizan técnicas de control robusto pata garantizar que las estrategias de control predictivo económico mantengan las prestaciones en lazo cerrado, incluso en presencia de incertidumbre. Los desarrollos de la tesis se ilustran con casos de estudio realistas. Para algunas de aplicaciones reales, se resuelven dificultades adicionales, como el uso de una estrategia de control de dos niveles para evitar incluir variables binarias en la optimización y el uso de la relajación de restricciones no lineales para tratar las ecuaciones algebraicas no lineales en el modelo descriptor en las redes de agua. Finalmente, se incluye también una contribución al diseño de estrategias de control con tolerancia a fallos para sistemas descriptores

Robust FDI/FTC using Set-membership Methods and Application to Real Case Studies

This paper reviews the use of set-membership methods in robust fault detection and isolation (FDI) and tolerant control (FTC). Set-membership methods use a deterministic unknown-but-bounded description of noise and parametric uncertainty (interval models). These methods aims to check the consistency between observed and predicted behavior by using simple sets to approximate the set of possible behaviors (in parameter or state space). When an inconsistency is detected a fault can be indicated, otherwise nothing can be stated. The same principle can be used to identify interval models for fault detection and to develop methods for fault tolerance evaluation. Finally, some real application of these methods will end the paper exemplifying the success of these methods in FDI/FTC.Postprint (published version

Designing application software in wide area network settings

Progress in methodologies for developing robust local area network software has not been matched by similar results for wide area settings. The design of application software spanning multiple local area environments is examined. For important classes of applications, simple design techniques are presented that yield fault tolerant wide area programs. An implementation of these techniques as a set of tools for use within the ISIS system is described

An Integrated Fuzzy Inference Based Monitoring, Diagnostic, and Prognostic System

To date the majority of the research related to the development and application of monitoring, diagnostic, and prognostic systems has been exclusive in the sense that only one of the three areas is the focus of the work. While previous research progresses each of the respective fields, the end result is a variable grab bag of techniques that address each problem independently. Also, the new field of prognostics is lacking in the sense that few methods have been proposed that produce estimates of the remaining useful life (RUL) of a device or can be realistically applied to real-world systems. This work addresses both problems by developing the nonparametric fuzzy inference system (NFIS) which is adapted for monitoring, diagnosis, and prognosis and then proposing the path classification and estimation (PACE) model that can be used to predict the RUL of a device that does or does not have a well defined failure threshold. To test and evaluate the proposed methods, they were applied to detect, diagnose, and prognose faults and failures in the hydraulic steering system of a deep oil exploration drill. The monitoring system implementing an NFIS predictor and sequential probability ratio test (SPRT) detector produced comparable detection rates to a monitoring system implementing an autoassociative kernel regression (AAKR) predictor and SPRT detector, specifically 80% vs. 85% for the NFIS and AAKR monitor respectively. It was also found that the NFIS monitor produced fewer false alarms. Next, the monitoring system outputs were used to generate symptom patterns for k-nearest neighbor (kNN) and NFIS classifiers that were trained to diagnose different fault classes. The NFIS diagnoser was shown to significantly outperform the kNN diagnoser, with overall accuracies of 96% vs. 89% respectively. Finally, the PACE implementing the NFIS was used to predict the RUL for different failure modes. The errors of the RUL estimates produced by the PACE-NFIS prognosers ranged from 1.2-11.4 hours with 95% confidence intervals (CI) from 0.67-32.02 hours, which are significantly better than the population based prognoser estimates with errors of ~45 hours and 95% CIs of ~162 hours