Comparison of different classification algorithms for fault detection and fault isolation in complex systems

Due to the lack of sufficient results seen in literature, feature extraction and classification methods of hydraulic systems appears to be somewhat challenging. This paper compares the performance of three classifiers (namely linear support vector machine (SVM), distance-weighted k-nearest neighbor (WKNN), and decision tree (DT) using data from optimized and non-optimized sensor set solutions. The algorithms are trained with known data and then tested with unknown data for different scenarios characterizing faults with different degrees of severity. This investigation is based solely on a data-driven approach and relies on data sets that are taken from experiments on the fuel system. The system that is used throughout this study is a typical fuel delivery system consisting of standard components such as a filter, pump, valve, nozzle, pipes, and two tanks. Running representative tests on a fuel system are problematic because of the time, cost, and reproduction constraints involved in capturing any significant degradation. Simulating significant degradation requires running over a considerable period; this cannot be reproduced quickly and is costly

Fault Classification of Nonlinear Small Sample Data through Feature Sub-Space Neighbor Vote

The fault classification of a small sample of high dimension is challenging, especially for a nonlinear and non-Gaussian manufacturing process. In this paper, a similarity-based feature selection and sub-space neighbor vote method is proposed to solve this problem. To capture the dynamics, nonlinearity, and non-Gaussianity in the irregular time series data, high order spectral features, and fractal dimension features are extracted, selected, and stacked in a regular matrix. To address the problem of a small sample, all labeled fault data are used for similarity decisions for a specific fault type. The distances between the new data and all fault types are calculated in their feature subspaces. The new data are classified to the nearest fault type by majority probability voting of the distances. Meanwhile, the selected features, from respective measured variables, indicate the cause of the fault. The proposed method is evaluated on a publicly available benchmark of a real semiconductor etching dataset. It is demonstrated that by using the high order spectral features and fractal dimensionality features, the proposed method can achieve more than 84% fault recognition accuracy. The resulting feature subspace can be used to match any new fault data to the fingerprint feature subspace of each fault type, and hence can pinpoint the root cause of a fault in a manufacturing process

Knowledge-based fault detection using time-frequency analysis

This work studies a fault detection method which analyzes sensor data for changes in their characteristics to detect the occurrence of faults in a dynamic system. The test system considered in this research is a Boeing-747 aircraft system and the faults considered are the actuator faults in the aircraft. The method is an alternative to conventional fault detection method and does not rely on analytical mathematical models but acquires knowledge about the system through experiments. In this work, we test the concept that the energy distribution of resolution than the windowed Fourier transform. Verification of the proposed methodology is carried in two parts. The first set of experiments considers entire data as a single window. Results show that the method effectively classifies the indicators by more that 85% as correct detections. The second set of experiments verifies the method for online fault detection. It is observed that the mean detection delay was less than 8 seconds. We also developed a simple graphical user interface to run the online fault detection

Oil and Gas flow Anomaly Detection on offshore naturally flowing wells using Deep Neural Networks

Dissertation presented as the partial requirement for obtaining a Master's degree in Data Science and Advanced Analytics, specialization in Data ScienceThe Oil and Gas industry, as never before, faces multiple challenges. It is being impugned for being dirty, a pollutant, and hence the more demand for green alternatives. Nevertheless, the world still has to rely heavily on hydrocarbons, since it is the most traditional and stable source of energy, as opposed to extensively promoted hydro, solar or wind power. Major operators are challenged to produce the oil more efficiently, to counteract the newly arising energy sources, with less of a climate footprint, more scrutinized expenditure, thus facing high skepticism regarding its future. It has to become greener, and hence to act in a manner not required previously. While most of the tools used by the Hydrocarbon E&P industry is expensive and has been used for many years, it is paramount for the industry’s survival and prosperity to apply predictive maintenance technologies, that would foresee potential failures, making production safer, lowering downtime, increasing productivity and diminishing maintenance costs. Many efforts were applied in order to define the most accurate and effective predictive methods, however data scarcity affects the speed and capacity for further experimentations. Whilst it would be highly beneficial for the industry to invest in Artificial Intelligence, this research aims at exploring, in depth, the subject of Anomaly Detection, using the open public data from Petrobras, that was developed by experts. For this research the Deep Learning Neural Networks, such as Recurrent Neural Networks with LSTM and GRU backbones, were implemented for multi-class classification of undesirable events on naturally flowing wells. Further, several hyperparameter optimization tools were explored, mainly focusing on Genetic Algorithms as being the most advanced methods for such kind of tasks. The research concluded with the best performing algorithm with 2 stacked GRU and the following vector of hyperparameters weights: [1, 47, 40, 14], which stand for timestep 1, number of hidden units 47, number of epochs 40 and batch size 14, producing F1 equal to 0.97%. As the world faces many issues, one of which is the detrimental effect of heavy industries to the environment and as result adverse global climate change, this project is an attempt to contribute to the field of applying Artificial Intelligence in the Oil and Gas industry, with the intention to make it more efficient, transparent and sustainable

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

Robot fault detection and remaining life estimation for predictive maintenance

Abstract In this work some possible solutions to implement a Robotics-oriented predictive maintenance approach are discussed. The data-driven methodology is described from the data collection to the design of an appropriate dataset and finally to the use of some of the most promising algorithms in the field of machine learning. The whole process is composed by several building blocks that can be combined to realize a data analysis on industrial robots. Some of the most promising techniques in Predictive Maintenance for Industrial machines were included in the proposed methodology, together with a Survival Analysis study, and then evaluated with proper performance metrics. Experimenting this methodology on a real use-case with Comau industrial robots showed the validity of the approach and opened to the inclusion of such a process in a service-oriented solution