Model based fault diagnosis for hybrid systems : application on chemical processes

The complexity and the size of the industrial chemical processes induce the monitoring of a growing number of process variables. Their knowledge is generally based on the measurements of system variables and on the physico-chemical models of the process. Nevertheless, this information is imprecise because of process and measurement noise. So the research ways aim at developing new and more powerful techniques for the detection of process fault. In this work, we present a method for the fault detection based on the comparison between the real system and the reference model evolution generated by the extended Kalman filter. The reference model is simulated by the dynamic hybrid simulator, PrODHyS. It is a general object-oriented environment which provides common and reusable components designed for the development and the management of dynamic simulation of industrial systems. The use of this method is illustrated through a didactic example relating to the field of Chemical Process System Engineering

Integration of a failure monitoring within a hybrid dynamic simulation environment

The complexity and the size of the industrial chemical processes induce the monitoring of a growing number of process variables. Their knowledge is generally based on the measurements of system variables and on the physico-chemical models of the process. Nevertheless this information is imprecise because of process and measurement noise. So the research ways aim at developing new and more powerful techniques for the detection of process fault. In this work, we present a method for the fault detection based on the comparison between the real system and the reference model evolution generated by the extended Kalman filter. The reference model is simulated by the dynamic hybrid simulator, PrODHyS. It is a general object-oriented environment which provides common and reusable components designed for the development and the management of dynamic simulation of industrial systems. The use of this method is illustrated through a didactic example relating to the field of Chemical Process System Engineering

Fault diagnosis and process monitoring through model-based case based reasoning

In this paper, we present a method for the fault detection and isolation based on the residual generation coupled with a case based reasoning approach. The main idea is to reconstruct the outputs of the system from the measurement using the extended Kalman filter. The estimations completed with qualitative information are included in a Case Based Reasoning system in order to discriminate the possible faults and to have a reliable diagnosis. The reference model is simulated by the dynamic hybrid simulator, PrODHyS. The use of this method is illustrated through an application in the field of chemical proces

A self-validating control system based approach to plant fault detection and diagnosis

An approach is proposed in which fault detection and diagnosis (FDD) tasks are distributed to separate FDD modules associated with each control system located throughout a plant. Intended specifically for those control systems that inherently eliminate steady state error, it is modular, steady state based, requires very little process specific information and therefore should be attractive to control systems implementers who seek economies of scale. The approach is applicable to virtually all types of process plant, whether they are open loop stable or not, have a type or class number of zero or not and so on. Based on qualitative reasoning, the approach is founded on the application of control systems theory to single and cascade control systems with integral action. This results in the derivation of cause-effect knowledge and fault isolation procedures that take into account factors like interactions between control systems, and the availability of non-control-loop-based sensors

Methods of Technical Prognostics Applicable to Embedded Systems

Hlavní cílem dizertace je poskytnutí uceleného pohledu na problematiku technické prognostiky, která nachází uplatnění v tzv. prediktivní údržbě založené na trvalém monitorování zařízení a odhadu úrovně degradace systému či jeho zbývající životnosti a to zejména v oblasti komplexních zařízení a strojů. V současnosti je technická diagnostika poměrně dobře zmapovaná a reálně nasazená na rozdíl od technické prognostiky, která je stále rozvíjejícím se oborem, který ovšem postrádá větší množství reálných aplikaci a navíc ne všechny metody jsou dostatečně přesné a aplikovatelné pro embedded systémy. Dizertační práce přináší přehled základních metod použitelných pro účely predikce zbývající užitné životnosti, jsou zde popsány metriky pomocí, kterých je možné jednotlivé přístupy porovnávat ať už z pohledu přesnosti, ale také i z pohledu výpočetní náročnosti. Jedno z dizertačních jader tvoří doporučení a postup pro výběr vhodné prognostické metody s ohledem na prognostická kritéria. Dalším dizertačním jádrem je představení tzv. částicového filtrovaní (particle filtering) vhodné pro model-based prognostiku s ověřením jejich implementace a porovnáním. Hlavní dizertační jádro reprezentuje případovou studii pro velmi aktuální téma prognostiky Li-Ion baterii s ohledem na trvalé monitorování. Případová studie demonstruje proces prognostiky založené na modelu a srovnává možné přístupy jednak pro odhad doby před vybitím baterie, ale také sleduje možné vlivy na degradaci baterie. Součástí práce je základní ověření modelu Li-Ion baterie a návrh prognostického procesu.The main aim of the thesis is to provide a comprehensive overview of technical prognosis, which is applied in the condition based maintenance, based on continuous device monitoring and remaining useful life estimation, especially in the field of complex equipment and machinery. Nowadays technical prognosis is still evolving discipline with limited number of real applications and is not so well developed as technical diagnostics, which is fairly well mapped and deployed in real systems. Thesis provides an overview of basic methods applicable for prediction of remaining useful life, metrics, which can help to compare the different approaches both in terms of accuracy and in terms of computational/deployment cost. One of the research cores consists of recommendations and guide for selecting the appropriate forecasting method with regard to the prognostic criteria. Second thesis research core provides description and applicability of particle filtering framework suitable for model-based forecasting. Verification of their implementation and comparison is provided. The main research topic of the thesis provides a case study for a very actual Li-Ion battery health monitoring and prognostics with respect to continuous monitoring. The case study demonstrates the prognostic process based on the model and compares the possible approaches for estimating both the runtime and capacity fade. Proposed methodology is verified on real measured data.

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

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

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