Advanced Process Monitoring for Industry 4.0

This book reports recent advances on Process Monitoring (PM) to cope with the many challenges raised by the new production systems, sensors and “extreme data” conditions that emerged with Industry 4.0. Concepts such as digital-twins and deep learning are brought to the PM arena, pushing forward the capabilities of existing methodologies to handle more complex scenarios. The evolution of classical paradigms such as Latent Variable modeling, Six Sigma and FMEA are also covered. Applications span a wide range of domains such as microelectronics, semiconductors, chemicals, materials, agriculture, as well as the monitoring of rotating equipment, combustion systems and membrane separation processes

Qualitative and Quantitative Approaches for Evaluation of Safety Risks in Coal Mines

The safety in underground coal mines continues to be a major problem in the Indian mining industry. Despite significant measures taken by the Directorate General of Mines Safety (DGMS) to reduce the number of mining accidents in underground coal mines, the number remains high. To improve the safety conditions, it has become a prerequisite to performing risk assessment for various operations in Indian mines. It is noted that many research studies conducted in the past are limited to either statistical analysis of accidents or study of single equipment or operation using qualitative and quantitative techniques. Limited work has been done to identify, analyse, and evaluate the safety risks of a complete underground coal mine in India. The present study attempts to determine the appropriate qualitative and quantitative risk assessment approaches for the evaluation of safety risks in Indian underground coal mines. This thesis addresses several important objectives as (i) to identify the type of safety risk analysis techniques suitable for evaluating various mining scenarios (ii) to identify and analyse the hazard factors and hazardous events that affects the safety in underground coal using the qualitative and quantitative approaches (iii) to evaluate the risk level (RL) of the hazardous factors/groups, hazardous events, and the overall mine using the proposed methodology. In this research work, the qualitative techniques, i.e. Failure Mode and Effects Analysis (FMEA), Workplace Risk Assessment and Control (WRAC), and the quantitative techniques, i.e. Fault Tree Analysis (FTA) and Event Tree Analysis (ETA) were applied in an underground coal mine to identify and analyse the hazard factors and hazard events. The analysis of FMEA and WRAC results concluded that the qualitative risk assessment is easy to execute and practical as they are not dependent on the historical data; rather they need experience and close examination. On the other hand, they may yield subjective results due to instinctive human assessment. The analysis of the FTA and ETA results concluded that the quantitative risk assessment could not be performed in Indian underground coal mines due to lack of probability, exposure, and consequence data. To overcome the mentioned problems in qualitative and quantitative techniques, a methodology was proposed for evaluation of the safety risks of hazard events, hazard groups, and overall mine. The proposed methodology is the unification of fuzzy logic, VIKOR (In Serbia: VIseKriterijumska Optimizacija I Kompromisno Resenje, that means: Multi-criteria Optimization and Compromise Solution), and Analytic Hierarchy Process (AHP) techniques. Because of the imprecise nature of the information available in the mining industry, fuzzy logic was employed to evaluate the risk of each hazardous event in terms of consequence, exposure, and probability. VIKOR as was used to rank the evaluated risk of hazardous events. AHP technique helps to determine the relative importance of the risk factors. Therefore, AHP technique was integrated into the risk model so that the risk evaluation can progress from hazardous event level to hazard factor level and finally to overall mine level. To reduce the calculation time significantly and to increase the speed of the proposed risk assessment process, a user-friendly Graphical User Interface (TRAM) was developed using the C# language through Microsoft Visual Studio 2015 and .Net libraries. The proposed methodology developed in this thesis was applied to six underground coal mines. The results presented the risk level of hazard events, hazards groups and overall mine of six mines. The mine-5 has the highest risk level among the evaluated mines. The ranking order of the mines observed based on the overall risk level is mine-5> mine-1 > mine-2 > mine-3 > mine-6 > mine-4. The results of the proposed methodology were compared with DGMS proposed rapid ranking method. This is observed that the proposed methodology presents better evaluation than other approaches. This study could help the mine management to prepare safety measures based on the risk rankings obtained. It may also aid to evaluate accurate risk levels with identified hazards while preparing risk management plans

Research and development of diagnostic algorithms to support fault accommodating control for emerging shipboard power system architectures

The U.S. Navy has proposed development of next generation warships utilising an increased amount of power electronics devices to improve flexibility and controllability. The high power density finite inertia network is envisioned to employ automated fault detection and diagnosis to aid timely remedial action. Integration of condition monitoring and fault diagnosis to form an intelligent power distribution system is anticipated to assist decision support for crew while enhancing security and mission availability. This broad research being in the conceptual stage has lack of benchmark systems to learn from. Thorough studies are required to successfully enable realising benefits offered by using increased power electronics and automation. Application of fundamental analysis techniques is necessary to meticulously understand dynamics of a novel system and familiarisation with associated risks and their effects. Additionally, it is vital to find ways of mitigating effects of identified risks. This thesis details the developing of a generalised methodology to help focus research into artificial intelligence (AI) based diagnostic techniques. Failure Mode and Effects Analysis (FMEA) is used in identifying critical parts of the architecture. Sneak Circuit Analysis (SCA) is modified to provide signals that differentiate faults at a component level of a dc-dc step down converter. These reliability analysis techniques combined with an appropriate AI-algorithm offer a potentially robust approach that can potentially be utilised for diagnosing faults within power electronic equipment anticipated to be used onboard the novel SPS. The proposed systematic methodology could be extended to other types of power electronic converters, as well as distinguishing subsystem level faults. The combination of FMEA, SCA with AI could also be used for providing enhanced decision support. This forms part of future research in this specific arena demonstrating the positives brought about by combining reliability analyses techniques with AI for next generation naval SPS.The U.S. Navy has proposed development of next generation warships utilising an increased amount of power electronics devices to improve flexibility and controllability. The high power density finite inertia network is envisioned to employ automated fault detection and diagnosis to aid timely remedial action. Integration of condition monitoring and fault diagnosis to form an intelligent power distribution system is anticipated to assist decision support for crew while enhancing security and mission availability. This broad research being in the conceptual stage has lack of benchmark systems to learn from. Thorough studies are required to successfully enable realising benefits offered by using increased power electronics and automation. Application of fundamental analysis techniques is necessary to meticulously understand dynamics of a novel system and familiarisation with associated risks and their effects. Additionally, it is vital to find ways of mitigating effects of identified risks. This thesis details the developing of a generalised methodology to help focus research into artificial intelligence (AI) based diagnostic techniques. Failure Mode and Effects Analysis (FMEA) is used in identifying critical parts of the architecture. Sneak Circuit Analysis (SCA) is modified to provide signals that differentiate faults at a component level of a dc-dc step down converter. These reliability analysis techniques combined with an appropriate AI-algorithm offer a potentially robust approach that can potentially be utilised for diagnosing faults within power electronic equipment anticipated to be used onboard the novel SPS. The proposed systematic methodology could be extended to other types of power electronic converters, as well as distinguishing subsystem level faults. The combination of FMEA, SCA with AI could also be used for providing enhanced decision support. This forms part of future research in this specific arena demonstrating the positives brought about by combining reliability analyses techniques with AI for next generation naval SPS

Multi criteria risk analysis of a subsea BOP system

The Subsea blowout preventer (BOP) which is latched to a subsea wellhead is one of several barriers in the well to prevent kicks and blowouts and it is the most important and critical equipment, as it becomes the last line of protection against blowout. The BOP system used in Subsea drilling operations is considered a Safety – Critical System, with a high severity consequence following its failure. Following past offshore blowout incidents such as the most recent Macondo in the Gulf of Mexico, there have been investigations, research, and improvements sought for improved understanding of the BOP system and its operation. This informs the need for a systematic re-evaluation of the Subsea BOP system to understand its associated risk and reliability and identify critical areas/aspects/components. Different risk analysis techniques were surveyed and the Failure modes effect and criticality analysis (FMECA) selected to be used to drive the study in this thesis. This is due to it being a simple proven cost effective process that can add value to the understanding of the behaviours and properties of a system, component, software, function or other. The output of the FMECA can be used to inform or support other key engineering tasks such as redesigning, enhanced qualification and testing activity or maintenance for greater inherent reliability and reduced risk potential. This thesis underscores the application of the FMECA technique to critique associated risk of the Subsea BOP system. System Functional diagrams was developed with boundaries defined, a FMECA were carried out and an initial select list of critical component failure modes identified. The limitations surrounding the confidence of the FMECA failure modes ranking outcome based on Risk priority number (RPN) is presented and potential variations in risk interpretation are discussed. The main contribution in this thesis is an innovative framework utilising Multicriteria decision making (MCDA) analysis techniques with consideration of fuzzy interval data is applied to the Subsea BOP system critical failure modes from the FMECA analysis. It utilised nine criticality assessment criteria deduced from expert consultation to obtain a more reliable ranking of failure modes. The MCDA techniques applied includes the technique for order of Preference for similarity to the Ideal Solution (TOPSIS), Fuzzy TOPSIS, TOPSIS with interval data, and Preference Ranking Organization Method for Enrichment of Evaluations (PROMETHEE). The outcome of the Multi-criteria analysis of the BOP system clearly shows failures of the Wellhead connector, LMRP hydraulic connector and Control system related failure as the Top 3 most critical failure with respect to a well control. The critical failure mode and components outcome from the analysis in this thesis is validated using failure data from industry database and a sensitivity analysis carried out. The importance of maintenance, testing and redundancy to the BOP system criticality was established by the sensitivity analysis. The potential for MCDA to be used for more specific analysis of criteria for a technology was demonstrated. Improper maintenance, inspection, testing (functional and pressure) are critical to the BOP system performance and sustenance of a high reliability level. Material selection and performance of components (seals, flanges, packers, bolts, mechanical body housings) relative to use environment and operational conditions is fundamental to avoiding failure mechanisms occurrence. Also worthy of notice is the contribution of personnel and organisations (by way of procedures to robustness and verification structure to ensure standard expected practices/rules are followed) to failures as seen in the root cause discussion. OEMs, operators and drilling contractors to periodically review operation scenarios relative to BOP system product design through the use of a Failure reporting analysis and corrective action system. This can improve design of monitoring systems, informs requirement for re-qualification of technology and/or next generation designs. Operations personnel are to correctly log in failures in these systems, and responsible Authority to ensure root cause analysis is done to uncover underlying issue initiating and driving failures

A Framework to Develop Anomaly Detection/Fault Isolation Architecture Using System Engineering Principles

For critical systems, timely recognition of an anomalous condition immediately starts the evaluation process. For complex systems, isolating the fault to a component or subsystem results in corrective action sooner so that undesired consequences may be minimized. There are many unique anomaly detection and fault isolation capabilities available with innovative techniques to quickly discover an issue and identify the underlying problems. This research develops a framework to aid in the selection of appropriate anomaly detection and fault isolation technology to augment a given system. To optimize this process, the framework employs a model based systems engineering approach. Specifically, a SysML model is generated that enables a system-level evaluation of alternative detection and isolation techniques, and subsequently identifies the preferable application(s) from these technologies A case study is conducted on a cryogenic liquid hydrogen system that was used to fuel the Space Shuttles at the Kennedy Space Center, Florida (and will be used to fuel the next generation Space Launch System rocket). This system is operated remotely and supports time-critical and highly hazardous operations making it a good candidate to augment with this technology. As the process depicted by the framework down-selects to potential applications for consideration, these too are tested in their ability to achieve required goals

A Statistical Evaluation of Risk Priority Numbers in Failure Modes and Effects Analysis Applied to the Prediction of Complex Systems

Complex systems such as military aircraft and naval ships are difficult to cost effectively maintain. Frequently, large-scale maintenance of complex systems (i.e., a naval vessel) is based on the reduction of the system to its base subcomponents and the use of manufacturer-suggested, time-directed, preventative maintenance, which is augmented during the systems lifecycle with predictive maintenance which assesses the system\u27s ability to perform its mission objectives. While preventative maintenance under certain conditions can increase reliability, preventative maintenance systems are often costly, increase down time, and allow for maintenance-induced failures, which may decrease the reliability of the system (Ebeling, 1997). This maintenance scheme ignores the complexity of the system it tries to maintain. By combining the base components or subsystems into a larger system, and introducing human interaction with the system, the complexity of the system creates a unique entity that cannot be completely understood by basing predictability of the system to perform tasks on the reduction of the system to its subcomponents. This study adds to the scholarly literature by developing a model, based on the traditional failure modes and effects analysis commonly used for research and development projects, to capture the effects of the human interaction with the system. Based on the ability of personnel assigned to operate and maintain the system, the severity of the system failure on the impact on the metasystems ability to perform its mission and the likelihood of the event of the failure to occur. Findings of the research indicate that the human interaction with the system, in as far as the ability of the personnel to repair and maintain the system, is a vital component in the ability to predict likelihood of the system failure and the prioritization of the risk of system failure, may be adequately captured for analysis through use of expert opinion elicitation. The use of the expert\u27s opinions may provide additional robustness to the modeling and analysis of system behavior in the event that failure occurs