Data-driven Soft Sensors in the Process Industry

In the last two decades Soft Sensors established themselves as a valuable alternative to the traditional means for the acquisition of critical process variables, process monitoring and other tasks which are related to process control. This paper discusses characteristics of the process industry data which are critical for the development of data-driven Soft Sensors. These characteristics are common to a large number of process industry fields, like the chemical industry, bioprocess industry, steel industry, etc. The focus of this work is put on the data-driven Soft Sensors because of their growing popularity, already demonstrated usefulness and huge, though yet not completely realised, potential. A comprehensive selection of case studies covering the three most important Soft Sensor application fields, a general introduction to the most popular Soft Sensor modelling techniques as well as a discussion of some open issues in the Soft Sensor development and maintenance and their possible solutions are the main contributions of this work

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

Fault Detection and Diagnosis Encyclopedia for Building Systems:A Systematic Review

This review aims to provide an up-to-date, comprehensive, and systematic summary of fault detection and diagnosis (FDD) in building systems. The latter was performed through a defined systematic methodology with the final selection of 221 studies. This review provides insights into four topics: (1) glossary framework of the FDD processes; (2) a classification scheme using energy system terminologies as the starting point; (3) the data, code, and performance evaluation metrics used in the reviewed literature; and (4) future research outlooks. FDD is a known and well-developed field in the aerospace, energy, and automotive sector. Nevertheless, this study found that FDD for building systems is still at an early stage worldwide. This was evident through the ongoing development of algorithms for detecting and diagnosing faults in building systems and the inconsistent use of the terminologies and definitions. In addition, there was an apparent lack of data statements in the reviewed articles, which compromised the reproducibility, and thus the practical development in this field. Furthermore, as data drove the research activity, the found dataset repositories and open code are also presented in this review. Finally, all data and documentation presented in this review are open and available in a GitHub repository

A review of model based and data driven methods targeting hardware systems diagnostics

System health diagnosis serves as an underpinning enabler for enhanced safety and optimized maintenance tasks in complex assets. In the past four decades, a wide-range of diagnostic methods have been proposed, focusing either on system or component level. Currently, one of the most quickly emerging concepts within the diagnostic community is system level diagnostics. This approach targets in accurately detecting faults and suggesting to the maintainers a component to be replaced in order to restore the system to a healthy state. System level diagnostics is of great value to complex systems whose downtime due to faults is expensive. This paper aims to provide a comprehensive review of the most recent diagnostics approaches applied to hardware systems. The main objective of this paper is to introduce the concept of system level diagnostics and review and evaluate the collated approaches. In order to achieve this, a comprehensive review of the most recent diagnostic methods implemented for hardware systems or components is conducted, highlighting merits and shortfalls

Establishment of a novel predictive reliability assessment strategy for ship machinery

There is no doubt that recent years, maritime industry is moving forward to novel and sophisticated inspection and maintenance practices. Nowadays maintenance is encountered as an operational method, which can be employed both as a profit generating process and a cost reduction budget centre through an enhanced Operation and Maintenance (O&M) strategy. In the first place, a flexible framework to be applicable on complex system level of machinery can be introduced towards ship maintenance scheduling of systems, subsystems and components.;This holistic inspection and maintenance notion should be implemented by integrating different strategies, methodologies, technologies and tools, suitably selected by fulfilling the requirements of the selected ship systems. In this thesis, an innovative maintenance strategy for ship machinery is proposed, namely the Probabilistic Machinery Reliability Assessment (PMRA) strategy focusing towards the reliability and safety enhancement of main systems, subsystems and maintainable units and components.;In this respect, the combination of a data mining method (k-means), the manufacturer safety aspects, the dynamic state modelling (Markov Chains), the probabilistic predictive reliability assessment (Bayesian Belief Networks) and the qualitative decision making (Failure Modes and Effects Analysis) is employed encompassing the benefits of qualitative and quantitative reliability assessment. PMRA has been clearly demonstrated in two case studies applied on offshore platform oil and gas and selected ship machinery.;The results are used to identify the most unreliability systems, subsystems and components, while advising suitable practical inspection and maintenance activities. The proposed PMRA strategy is also tested in a flexible sensitivity analysis scheme.There is no doubt that recent years, maritime industry is moving forward to novel and sophisticated inspection and maintenance practices. Nowadays maintenance is encountered as an operational method, which can be employed both as a profit generating process and a cost reduction budget centre through an enhanced Operation and Maintenance (O&M) strategy. In the first place, a flexible framework to be applicable on complex system level of machinery can be introduced towards ship maintenance scheduling of systems, subsystems and components.;This holistic inspection and maintenance notion should be implemented by integrating different strategies, methodologies, technologies and tools, suitably selected by fulfilling the requirements of the selected ship systems. In this thesis, an innovative maintenance strategy for ship machinery is proposed, namely the Probabilistic Machinery Reliability Assessment (PMRA) strategy focusing towards the reliability and safety enhancement of main systems, subsystems and maintainable units and components.;In this respect, the combination of a data mining method (k-means), the manufacturer safety aspects, the dynamic state modelling (Markov Chains), the probabilistic predictive reliability assessment (Bayesian Belief Networks) and the qualitative decision making (Failure Modes and Effects Analysis) is employed encompassing the benefits of qualitative and quantitative reliability assessment. PMRA has been clearly demonstrated in two case studies applied on offshore platform oil and gas and selected ship machinery.;The results are used to identify the most unreliability systems, subsystems and components, while advising suitable practical inspection and maintenance activities. The proposed PMRA strategy is also tested in a flexible sensitivity analysis scheme

Considerations for a design and operations knowledge support system for Space Station Freedom

Engineering and operations of modern engineered systems depend critically upon detailed design and operations knowledge that is accurate and authoritative. A design and operations knowledge support system (DOKSS) is a modern computer-based information system providing knowledge about the creation, evolution, and growth of an engineered system. The purpose of a DOKSS is to provide convenient and effective access to this multifaceted information. The complexity of Space Station Freedom's (SSF's) systems, elements, interfaces, and organizations makes convenient access to design knowledge especially important, when compared to simpler systems. The life cycle length, being 30 or more years, adds a new dimension to space operations, maintenance, and evolution. Provided here is a review and discussion of design knowledge support systems to be delivered and operated as a critical part of the engineered system. A concept of a DOKSS for Space Station Freedom (SSF) is presented. This is followed by a detailed discussion of a DOKSS for the Lyndon B. Johnson Space Center and Work Package-2 portions of SSF

A Probabilistic Framework To Diagnose Faults in Air Handling Units.

Air handling unit (AHU) is one of the most extensively used equipment in large commercial buildings. This device is typically customized and lacks quality system integration, which can result in, hardwire failures and controller errors. Air handling unit Performance Assessment Rules (APAR) is a fault detection tool that uses a set of expert rules derived from mass and energy balances to detect faults in air handling units. Although APAR has many advantages over other methods, for example, no training data required and easy to implement commercially, most of the time it is unable to provide the diagnosis of the faults. There is no established way to have the correct diagnosis for rule based fault detection system. In this study, we developed a new way to detect and diagnose faults in AHU through combining APAR rules and Bayesian Belief Network. BBN is used as a decision support tool for rule-based expert system. BBN is highly capable to prioritize faults when multiple rules are satisfied simultaneously. The proposed model tested with real time measured data of a campus building at University of Texas at San Antonio (UTSA)

NASA space station automation: AI-based technology review. Executive summary

Research and Development projects in automation technology for the Space Station are described. Artificial Intelligence (AI) based technologies are planned to enhance crew safety through reduced need for EVA, increase crew productivity through the reduction of routine operations, increase space station autonomy, and augment space station capability through the use of teleoperation and robotics

Fault Detection and RUL Estimation for Railway HVAC Systems Using a Hybrid Model-Based Approach

Heating, ventilation, and air conditioning (HVAC) systems installed in a passenger train carriage are critical systems, whose failures can affect people or the environment. This, together with restrictive regulations, results in the replacement of critical components in initial stages of degradation, as well as a lack of data on advanced stages of degradation. This paper proposes a hybrid model-based approach (HyMA) to overcome the lack of failure data on a HVAC system installed in a passenger train carriage. The proposed HyMA combines physics-based models with data-driven models to deploy diagnostic and prognostic processes for a complex and critical system. The physics-based model generates data on healthy and faulty working conditions; the faults are generated in different levels of degradation and can appear individually or together. A fusion of synthetic data and measured data is used to train, validate, and test the proposed hybrid model (HyM) for fault detection and diagnostics (FDD) of the HVAC system. The model obtains an accuracy of 92.60%. In addition, the physics-based model generates run-to-failure data for the HVAC air filter to develop a remaining useful life (RUL) prediction model, the RUL estimations performed obtained an accuracy in the range of 95.21–97.80% Both models obtain a remarkable accuracy. The development presented will result in a tool which provides relevant information on the health state of the HVAC system, extends its useful life, reduces its life cycle cost, and improves its reliability and availability; thus enhancing the sustainability of the system.Research was funded by the Basque Government, through ELKARTEK (ref. KK-2020/00049) funding grant