Data-based fault detection in chemical processes: Managing records with operator intervention and uncertain labels

Developing data-driven fault detection systems for chemical plants requires managing uncertain data labels and dynamic attributes due to operator-process interactions. Mislabeled data is a known problem in computer science that has received scarce attention from the process systems community. This work introduces and examines the effects of operator actions in records and labels, and the consequences in the development of detection models. Using a state space model, this work proposes an iterative relabeling scheme for retraining classifiers that continuously refines dynamic attributes and labels. Three case studies are presented: a reactor as a motivating example, flooding in a simulated de-Butanizer column, as a complex case, and foaming in an absorber as an industrial challenge. For the first case, detection accuracy is shown to increase by 14% while operating costs are reduced by 20%. Moreover, regarding the de-Butanizer column, the performance of the proposed strategy is shown to be 10% higher than the filtering strategy. Promising results are finally reported in regard of efficient strategies to deal with the presented problemPeer ReviewedPostprint (author's final draft

Robust detection, isolation and accommodation for sensor failures

The objective is to extend the recent advances in robust control system design of multivariable systems to sensor failure detection, isolation, and accommodation (DIA), and estimator design. This effort provides analysis tools to quantify the trade-off between performance robustness and DIA sensitivity, which are to be used to achieve higher levels of performance robustness for given levels of DIA sensitivity. An innovations-based DIA scheme is used. Estimators, which depend upon a model of the process and process inputs and outputs, are used to generate these innovations. Thresholds used to determine failure detection are computed based on bounds on modeling errors, noise properties, and the class of failures. The applicability of the newly developed tools are demonstrated on a multivariable aircraft turbojet engine example. A new concept call the threshold selector was developed. It represents a significant and innovative tool for the analysis and synthesis of DiA algorithms. The estimators were made robust by introduction of an internal model and by frequency shaping. The internal mode provides asymptotically unbiased filter estimates.The incorporation of frequency shaping of the Linear Quadratic Gaussian cost functional modifies the estimator design to make it suitable for sensor failure DIA. The results are compared with previous studies which used thresholds that were selcted empirically. Comparison of these two techniques on a nonlinear dynamic engine simulation shows improved performance of the new method compared to previous technique

LPV model-based robust diagnosis of flight actuator faults

A linear parameter-varying (LPV) model-based synthesis, tuning and assessment methodology is developed and applied for the design of a robust fault detection and diagnosis (FDD) system for several types of flight actuator faults such as jamming, runaway, oscillatory failure, or loss of efficiency. The robust fault detection is achieved by using a synthesis approach based on an accurate approximation of the nonlinear actuator-control surface dynamics via an LPV model and an optimal tuning of the free parameters of the FDD system using multi-objective optimization techniques. Real-time signal processing is employed for identification of different fault types. The assessment of the FDD system robustness has been performed using both standard Monte Carlo methods as well as advanced worst-case search based optimization-driven robustness analysis. A supplementary industrial validation performed on the AIRBUS actuator test bench for the monitoring of jamming, confirmed the satisfactory performance of the FDD system in a true industrial setting

On-line estimation approaches to fault-tolerant control of uncertain systems

This thesis is concerned with fault estimation in Fault-Tolerant Control (FTC) and as such involves the joint problem of on-line estimation within an adaptive control system. The faults that are considered are significant uncertainties affecting the control variables of the process and their estimates are used in an adaptive control compensation mechanism. The approach taken involves the active FTC, as the faults can be considered as uncertainties affecting the control system. The engineering (application domain) challenges that are addressed are: (1) On-line model-based fault estimation and compensation as an FTC problem, for systems with large but bounded fault magnitudes and for which the faults can be considered as a special form of dynamic uncertainty. (2) Fault-tolerance in the distributed control of uncertain inter-connected systems The thesis also describes how challenge (1) can be used in the distributed control problem of challenge (2). The basic principle adopted throughout the work is that the controller has two components, one involving the nominal control action and the second acting as an adaptive compensation for significant uncertainties and fault effects. The fault effects are a form of uncertainty which is considered too large for the application of passive FTC methods. The thesis considers several approaches to robust control and estimation: augmented state observer (ASO); sliding mode control (SMC); sliding mode fault estimation via Sliding Mode Observer (SMO); linear parameter-varying (LPV) control; two-level distributed control with learning coordination

Robust model-based fault estimation and fault-tolerant control : towards an integration

To maintain robustly acceptable system performance, fault estimation (FE) is adopted to reconstruct fault signals and a fault-tolerant control (FTC) controller is employed to compensate for the fault effects. The inevitably existing system and estimation uncertainties result in the so-called bi-directional robustness interactions defined in this work between the FE and FTC functions, which gives rise to an important and challenging yet open integrated FE/FTC design problem concerned in this thesis. An example of fault-tolerant wind turbine pitch control is provided as a practical motivation for integrated FE/FTC design.To achieve the integrated FE/FTC design for linear systems, two strategies are proposed. A H∞ optimization based approach is first proposed for linear systems with differentiable matched faults, using augmented state unknown input observer FE and adaptive sliding mode FTC. The integrated design is converted into an observer-based robust control problem solved via a single-step linear matrix inequality formulation.With the purpose of an integrated design with more freedom and also applicable for a range of general fault scenarios, a decoupling approach is further proposed. This approach can estimate and compensate unmatched non-differentiable faults and perturbations by combined adaptive sliding mode augmented state unknown input observer and backstepping FTC controller. The observer structure renders a recovery of the Separation Principle and allows great freedom for the FE/FTC designs.Integrated FE/FTC design strategies are also developed for Takagi-Sugeno fuzzy modelling nonlinear systems, Lipschitz nonlinear systems, and large-scale interconnected systems, based on extensions of the H∞ optimization approach for linear systems.Tutorial examples are used to illustrate the design strategies for each approach. Physical systems, a 3-DOF (degree-of-freedom) helicopter and a 3-machine power system, are used to provide further evaluation of the proposed integrated FE/FTC strategies. Future research on this subject is also outlined

Robust control examples applied to a wind turbine simulated model

Wind turbine plants are complex dynamic and uncertain processes driven by stochastic inputs and disturbances, as well as different loads represented by gyroscopic, centrifugal and gravitational forces. Moreover, as their aerodynamic models are nonlinear, both modeling and control become challenging problems. On the one hand, high-fidelity simulators should contain different parameters and variables in order to accurately describe the main dynamic system behavior. Therefore, the development of modeling and control for wind turbine systems should consider these complexity aspects. On the other hand, these control solutions have to include the main wind turbine dynamic characteristics without becoming too complicated. The main point of this paper is thus to provide two practical examples of the development of robust control strategies when applied to a simulated wind turbine plant. Extended simulations with the wind turbine benchmark model and the Monte Carlo tool represent the instruments for assessing the robustness and reliability aspects of the developed control methodologies when the model-reality mismatch and measurement errors are also considered. Advantages and drawbacks of these regulation methods are also highlighted with respect to different control strategies via proper performance metrics.Wind turbine plants are complex dynamic and uncertain processes driven by stochastic inputs and disturbances, as well as different loads represented by gyroscopic, centrifugal and gravitational forces. Moreover, as their aerodynamic models are nonlinear, both modeling and control become challenging problems. On the one hand, high-fidelity simulators should contain different parameters and variables in order to accurately describe the main dynamic system behavior. Therefore, the development of modeling and control for wind turbine systems should consider these complexity aspects. On the other hand, these control solutions have to include the main wind turbine dynamic characteristics without becoming too complicated. The main point of this paper is thus to provide two practical examples of the development of robust control strategies when applied to a simulated wind turbine plant. Extended simulations with the wind turbine benchmark model and the Monte Carlo tool represent the instruments for assessing the robustness and reliability aspects of the developed control methodologies when the model-reality mismatch and measurement errors are also considered. Advantages and drawbacks of these regulation methods are also highlighted with respect to different control strategies via proper performance metrics

Fault-tolerant neuro adaptive constrained control of wind turbines for power regulation with uncertain wind speed variation

This paper presents a novel adaptive fault-tolerant neural-based control design for wind turbines with an unknown dynamic and unknown wind speed. By utilizing the barrier Lyapunov function in the analysis of the Lyapunov direct method, the constrained behavior of the system is provided in which the rotor speed, its variation, and generated power remain in the desired bounds. In addition, input saturation is also considered in terms of smooth pitch actuator bounding. Furthermore, by utilizing a Nussbaum-type function in designing the control algorithm, the unpredictable wind speed variation is captured without requiring accurate wind speed measurement, observation, or estimation. Moreover, with the proposed adaptive analytic algorithms, together with the use of radial basis function neural networks, a robust, adaptive, and fault-tolerant control scheme is developed without the need for precise information about the wind turbine model nor the pitch actuator faults. Additionally, the computational cost of the resultant control law is reduced by utilizing a dynamic surface control technique. The effectiveness of the developed design is verified using theoretical analysis tools and illustrated by numerical simulations on a high-fidelity wind turbine benchmark model with different fault scenarios. Comparison of the achieved results to the ones that can be obtained via an available industrial controller shows the advantages of the proposed scheme