Towards a unified approach to detection of faults and cyber-attacks in industrial installations

© 2021 IEEE. Personal use of this material is permitted. Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting /republishing this material for advertising or promotional purposes, creating new collective works, for resale or redistribution to servers or lists, or reuse of any copyrighted component of this work in other worksThis paper investigates enhancing the ability to detect cyber-attacks by using information and methods related to fault detection. An experimental stand, and an associated simulator have been constructed to enable tests of combined cyber attacks and faults in industrial processes, and, possibly, to distinguish between them. Some scenarios of cyber attacks have been presented, analysed theoretically and then tested on the simulator, demonstrating that detection of cyber attacks by this method is possible.Peer ReviewedPostprint (author's final draft

Real-Time Fault Diagnosis of Permanent Magnet Synchronous Motor and Drive System

Permanent Magnet Synchronous Motors (PMSMs) have gained massive popularity in industrial applications such as electric vehicles, robotic systems, and offshore industries due to their merits of efficiency, power density, and controllability. PMSMs working in such applications are constantly exposed to electrical, thermal, and mechanical stresses, resulting in different faults such as electrical, mechanical, and magnetic faults. These faults may lead to efficiency reduction, excessive heat, and even catastrophic system breakdown if not diagnosed in time. Therefore, developing methods for real-time condition monitoring and detection of faults at early stages can substantially lower maintenance costs, downtime of the system, and productivity loss. In this dissertation, condition monitoring and detection of the three most common faults in PMSMs and drive systems, namely inter-turn short circuit, demagnetization, and sensor faults are studied. First, modeling and detection of inter-turn short circuit fault is investigated by proposing one FEM-based model, and one analytical model. In these two models, efforts are made to extract either fault indicators or adjustments for being used in combination with more complex detection methods. Subsequently, a systematic fault diagnosis of PMSM and drive system containing multiple faults based on structural analysis is presented. After implementing structural analysis and obtaining the redundant part of the PMSM and drive system, several sequential residuals are designed and implemented based on the fault terms that appear in each of the redundant sets to detect and isolate the studied faults which are applied at different time intervals. Finally, real-time detection of faults in PMSMs and drive systems by using a powerful statistical signal-processing detector such as generalized likelihood ratio test is investigated. By using generalized likelihood ratio test, a threshold was obtained based on choosing the probability of a false alarm and the probability of detection for each detector based on which decision was made to indicate the presence of the studied faults. To improve the detection and recovery delay time, a recursive cumulative GLRT with an adaptive threshold algorithm is implemented. As a result, a more processed fault indicator is achieved by this recursive algorithm that is compared to an arbitrary threshold, and a decision is made in real-time performance. The experimental results show that the statistical detector is able to efficiently detect all the unexpected faults in the presence of unknown noise and without experiencing any false alarm, proving the effectiveness of this diagnostic approach.publishedVersio

FAULT DIAGNOSIS TOOLS IN MULTIVARIATE STATISTICAL PROCESS AND QUALITY CONTROL

[EN] An accurate fault diagnosis of both, faults sensors and real process faults have become more and more important for process monitoring (minimize downtime, increase safety of plant operation and reduce the manufacturing cost). Quick and correct fault diagnosis is required in order to put back on track our processes or products before safety or quality can be compromised. In the study and comparison of the fault diagnosis methodologies, this thesis distinguishes between two different scenarios, methods for multivariate statistical quality control (MSQC) and methods for latent-based multivariate statistical process control: (Lb-MSPC). In the first part of the thesis the state of the art on fault diagnosis and identification (FDI) is introduced. The second part of the thesis is devoted to the fault diagnosis in multivariate statistical quality control (MSQC). The rationale of the most extended methods for fault diagnosis in supervised scenarios, the requirements for their implementation, their strong points and their drawbacks and relationships are discussed. The performance of the methods is compared using different performance indices in two different process data sets and simulations. New variants and methods to improve the diagnosis performance in MSQC are also proposed. The third part of the thesis is devoted to the fault diagnosis in latent-based multivariate statistical process control (Lb-MSPC). The rationale of the most extended methods for fault diagnosis in supervised Lb-MSPC is described and one of our proposals, the Fingerprints contribution plots (FCP) is introduced. Finally the thesis presents and compare the performance results of these diagnosis methods in Lb-MSPC. The diagnosis results in two process data sets are compared using a new strategy based in the use of the overall sensitivity and specificity[ES] La realización de un diagnóstico preciso de los fallos, tanto si se trata de fallos de sensores como si se trata de fallos de procesos, ha llegado a ser algo de vital importancia en la monitorización de procesos (reduce las paradas de planta, incrementa la seguridad de la operación en planta y reduce los costes de producción). Se requieren diagnósticos rápidos y correctos si se quiere poder recuperar los procesos o productos antes de que la seguridad o la calidad de los mismos se pueda ver comprometida. En el estudio de las diferentes metodologías para el diagnóstico de fallos esta tesis distingue dos escenarios diferentes, métodos para el control de estadístico multivariante de la calidad (MSQC) y métodos para el control estadístico de procesos basados en el uso de variables latentes (Lb-MSPC). En la primera parte de esta tesis se introduce el estado del arte sobre el diagnóstico e identificación de fallos (FDI). La segunda parte de la tesis está centrada en el estudio del diagnóstico de fallos en control estadístico multivariante de la calidad. Se describen los fundamentos de los métodos más extendidos para el diagnóstico en escenarios supervisados, sus requerimientos para su implementación sus puntos fuertes y débiles y sus posibles relaciones. Los resultados de diagnóstico de los métodos es comparado usando diferentes índices sobre los datos procedentes de dos procesos reales y de diferentes simulaciones. En la tesis se proponen nuevas variantes que tratan de mejorar los resultados obtenidos en MSQC. La tercera parte de la tesis está dedicada al diagnóstico de fallos en control estadístico multivariante de procesos basados en el uso de modelos de variables latentes (Lb-MSPC). Se describe los fundamentos de los métodos mas extendidos en el diagnóstico de fallos en Lb-MSPC supervisado y se introduce una de nuestras propuestas, el fingerprint contribution plot (FCP). Finalmente la tesis presenta y compara los resultados de diagnóstico de los métodos propuestos en Lb-MSPC. Los resultados son comparados sobre los datos de dos procesos usando una nueva estrategia basada en el uso de la sensitividad y especificidad promedia.[CA] La realització d'un diagnòstic precís de les fallades, tant si es tracta de fallades de sensors com si es tracta de fallades de processos, ha arribat a ser de vital importància en la monitorització de processos (reduïx les parades de planta, incrementa la seguretat de l'operació en planta i reduïx els costos de producció) . Es requerixen diagnòstics ràpids i correctes si es vol poder recuperar els processos o productes abans de que la seguretat o la qualitat dels mateixos es puga veure compromesa. En l'estudi de les diferents metodologies per al diagnòstic de fallades esta tesi distingix dos escenaris diferents, mètodes per al control estadístic multivariant de la qualitat (MSQC) i l mètodes per al control estadístic de processos basats en l'ús de variables latents (Lb-MSPC). En la primera part d'esta tesi s'introduïx l'estat de l'art sobre el diagnòstic i identificació de fallades (FDI). La segona part de la tesi està centrada en l'estudi del diagnòstic de fallades en control estadístic multivariant de la qualitat. Es descriuen els fonaments dels mètodes més estesos per al diagnòstic en escenaris supervisats, els seus requeriments per a la seua implementació els seus punts forts i febles i les seues possibles relacions. Els resultats de diagnòstic dels mètodes és comparat utilitzant diferents índexs sobre les dades procedents de dos processos reals i de diferents simulacions. En la tesi es proposen noves variants que tracten de millorar els resultats obtinguts en MSQC. La tercera part de la tesi està dedicada al diagnòstic de fallades en control estadístic multivariant de processos basat en l'ús de models de variables latents (Lb-MSPC). Es descriu els fonaments dels mètodes més estesos en el diagnòstic de fallades en MSPC supervisat i s'introdueix una nova proposta, el fingerprint contribution plot (FCP). Finalment la tesi presenta i compara els resultats de diagnòstic dels mètodes proposats en MSPC. Els resultats són comparats sobre les dades de dos processos utilitzant una nova estratègia basada en l'ús de la sensibilitat i especificitat mitjana.Vidal Puig, S. (2016). FAULT DIAGNOSIS TOOLS IN MULTIVARIATE STATISTICAL PROCESS AND QUALITY CONTROL [Tesis doctoral no publicada]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/61292TESI

Unknown input observer approaches to robust fault diagnosis

This thesis focuses on the development of the model-based fault detection and isolation /fault detection and diagnosis (FDI/FDD) techniques using the unknown input observer (UIO) methodology. Using the UI de-coupling philosophy to tackle the robustness issue, a set of novel fault estimation (FE)-oriented UIO approaches are developed based on the classical residual generation-oriented UIO approach considering the time derivative characteristics of various faults. The main developments proposed are:- Implement the residual-based UIO design on a high fidelity commercial aircraft benchmark model to detect and isolate the elevator sensor runaway fault. The FDI design performance is validated using a functional engineering simulation (FES) system environment provided through the activity of an EU FP7 project Advanced Fault Diagnosis for Safer Flight Guidance and Control (ADDSAFE).- Propose a linear time-invariant (LTI) model-based robust fast adaptive fault estimator (RFAFE) with UI de-coupling to estimate the aircraft elevator oscillatory faults considered as actuator faults.- Propose a UI-proportional integral observer (UI-PIO) to estimate actuator multiplicative faults based on an LTI model with UI de-coupling and with added H∞ optimisation to reduce the effects of the sensor noise. This is applied to an example on a hydraulic leakage fault (multiplicative fault) in a wind turbine pitch actuator system, assuming that thefirst derivative of the fault is zero. - Develop an UI–proportional multiple integral observer (UI-PMIO) to estimate the system states and faults simultaneously with the UI acting on the system states. The UI-PMIO leads to a relaxed condition of requiring that the first time derivative of the fault is zero instead of requiring that the finite time fault derivative is zero or bounded. - Propose a novel actuator fault and state estimation methodology, the UI–proportional multiple integral and derivative observer (UI-PMIDO), inspired by both of the RFAFE and UI-PMIO designs. This leads to an observer with the comprehensive feature of estimating faults with bounded finite time derivatives and ensuring fast FE tracking response.- Extend the UI-PMIDO theory based on LTI modelling to a linear parameter varying (LPV) model approach for FE design. A nonlinear two-link manipulator example is used to illustrate the power of this method

Sensor Fault Detection and Isolation System

The purpose of this research is to develop a Fault Detection and Isolation (FDI) system which is capable to diagnosis multiple sensor faults in nonlinear cases. In order to lead this study closer to real world applications in oil industries, the system parameters of the applied system are assumed to be unknown. In the first step of the proposed method, phase space reconstruction techniques are used to reconstruct the phase space of the applied system. This step is aimed to infer the system property by the collected sensor measurements. The second step is to use the reconstructed phase space to predict future sensor measurements, and residual signals are generated by comparing the actually measured measurements to the predicted measurements. Since, in practice, residual signals will not perfectly equal to zero in the fault-free situation, Multiple Hypothesis Shiryayev Sequential Probability Test (MHSSPT) is introduced to further process those residual signals, and the diagnostic results are presented in probability. In addition, the proposed method is extended to a non-stationary case by using the conservation/dissipation property in phase space. The proposed method is examined by both of simulated data and real process data to support that it is capable of detecting and isolating multiple sensor faults in nonlinear cases. In the section of simulation results, a three tank model is introduced for generating simulated data. The three tank model is modeled according to a nonlinear laboratory setup DTS200. On the other hand, in the section of experimental results, the real process data collected from a sugar factory actuator system are used to examine the proposed method. According to our results obtained from simulations and experiments, the proposed method is capable to indicate both of healthy and faulty situations. These results further confirm that the proposed method is able to deal with not only simulated data but also real process data

Development and experimental verification of data‐driven approaches to real‐time energy monitoring and diagnosis of telecommunication sites

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Residual generation and fault diagnosis of rechargeable lead-acid batteries

In many process and manufacturing industries, early detection of faults has great practical importance. Since it saves time and cost involved in the repairing of the equipment. Qualitative methods such as neural networks and fuzzy logic are popular tools in model based fault detection and classification of nonlinear dynamic systems. Since it is difficult to accurately model these kind of systems. In the first part of this work, neural network and adaptive neuro-fuzzy logic methods are used in the modeling of a water-tank system to produce residuals for fault classification. This study shows that neural networks have better performance but longer training time compared to the adaptive neuro-fuzzy logic. The second part of this research investigates the classification tree and Fisher Discriminant Analysis (FDA) approaches in fault classification of nonlinear dynamic systems. Comparing the performance of these approaches indicates that FDA method results in longer computational time but lower tree size for high dimensional training data. The contributions of this thesis are modeling and fault diagnosis of lead-acid battery system using qualitative techniques in combination with statistical methods such as classification tree

Model based fault detection and isolation approach for actuator and sensor faults in a UAV

Thesis (MEng)--Stellenbosch University, 2021.ENGLISH ABSTRACT: This thesis presents the design and validation of model-based fault detection and isolation (FDI) approach for unmanned aerial vehicles (UAV). In safety-critical sys- tems such as chemical, nuclear plants and passenger aircraft, FDI is typically founded on hardware redundancy. In hardware redundancy, multiple actuators are spatially distributed to localise faults quickly, and sensor measurements are compared for consistency. The primary drawback with hardware redundancy is the increased installation complexity, weight, and costs. With modern computing technologies, model-based FDI offers a cost-effective, iterative and efficient FDI design process, verifiable with high fidelity computer-aided simulation (CAS). This thesis investigates the application of the Two-Stage Kalman filter (TSKF) to the problem of FDI. The TSKF solves the main deficiencies faced with the aug- mented state Kalman filter (ASKF), namely, numerical instability in ill-conditioned systems, and computational inefficiency where large parameter vectors are aug- mented. The TSKF approach utilises two parallel reduced-order KFs to estimate the system state and the parameter vectors separately. The UAV’s two rudders are not "isolable" because they produce identical moments. A novel active FDI (AFDI) method is proposed to isolate rudder actuator faults. The FDI displays high noise sensitivity under the evere Dryden turbulence model, resulting in high false detection and missed detection rates. A novel adap- tive technique is proposed to improve the robustness and sensitivity of the FDI. Unlike most methods which rely on a single scaling factor, the proposed adaptation technique employs multiple factors to weight the spread of fault parameter covari- ance matrix in the direction of flow of information, resulting in selective adaptation. Fault parameter variations are nonuniform in time and space. A static alarm threshold will induce high false alarms or missed alarms when set to low or too high, respectively. A novel adaptive threshold based on the normalised innovation squared (NIS) is proposed. A Monte Carlo campaign is carried out to validate the FDI while fault-sizes, the aircraft’s physical parameters, and disturbances are scat- tered, each with a distinct mean dispersion. The proposed strategy exhibits high robustness to noise and sensitivity to faults which indicates a reliable FDI.AFRIKAANSE OPSOMMING: Hierdie tesis beskryf die ontwerp en validering van ‘n model-gebaseerde foutop- sporing en isolasie (“fault deteciton and isolation (FDI)”) tegniek vir onbemande lugvoertuie (“unmanned aerial vehicles (UAVs)”). In veiligheidskritieke stelsels soos chemiese aanlegte, kernkragaanlegte, en passasiersvliegtuie, word FDI gewoon- lik gebaseer op hardeware-oortolligheid. Vir hardeware-oortolligheid word verskeie aktueerders ruimtelik versprei om foute vinnig op te spoor, en sensormetings word vergelyk vir ooreenstemming. Die primêre nadeel van hardeware-oortolligheid is die verhoogde installasie-kompleksiteit, gewig en koste. Met moderne rekenaarteg- nologieë bied model-gebaseerde FDI ’n koste-effektiewe, iteratiewe en doeltref-fende FDI-ontwerpproses met ‘n hoë betroubaarheid wat bevestig kan word met rekenaargesteunde simulasie. Hierdie tesis ondersoek die toepassing van die twee-stadium Kalman filter (“two- stage Kalman filter (TSKF)”) op die probleem van FDI. Die TSKF los die belangrik- ste tekortkominge van die uitgebredie-toestand Kalman-filter (“augmented state Kalman filter (ASKF)”) op, naamlik numeriese onstabiliteit in swak gekondisioneerde stelsels, en berekeningsondoeltreffendheid waar groot parametervektore bygevoeg word. Die TSKF-benadering gebruik twee parallelle Kalman filters met vermin- derde orde om die stelseltoestand en die parametervektore afsonderlik af te skat. Die UAV se twee roere (“rudders”) is egter nie “isoleerbaar” nie omdat dit hulle identiese draaimoment veroorsaak. ’n Nuwe aktiewe FDI-metode (AFDI) word voorgestel om die roeraktueerderfoute te isoleer. Die FDI vertoon hoë sensitiwiteit vir geraas vanaf erge turbulensie soos gemod- elleer deur die Dryden-turbulensie-model, wat lei tot ‘n groot aantal vals deteksies en gemiste deteksies. ’n Nuwe aanpassingstegniek word voorgestel om die robu- ustheid en sensitiwiteit van die FDI te verbeter. Anders as die meeste metodes wat op een enkele skaalfaktor staatmaak, gebruik die voorgestelde aanpassingstegniek verskeie faktore om die verspreiding van die foutparameterkovariansiematriks in die rigting van informasievloei te weeg, wat lei tot selektiewe aanpassing. Foutparametervariasies is nie eenvormig in tyd of ruimte nie. ’n Statiese alar- mdrempel sal hoë vals deteksies of gemiste deteksies veroorsaak as dit onderskei-delik óf te laag óf te hoog gestel is. ’n Nuwe aanpassingsdrempel wat gebaseer is op die genormaliseerde innovasie kwadraat (NIS) word voorgestel. ’n Monte Carlo simulasieveldtog is uitgevoer om die FDI te toets met die foutgroottes, die fisiese parameters van die vliegtuig, en die steurings lukraak gevarieer elk met ’n duide- like gemiddelde verspreiding. Die voorgestelde strategie vertoon ’n hoë robuus- theid vir geraas en sensitiwiteit vir foute, wat dui op ’n betroubare FDI

Development of a Data Driven Multiple Observer and Causal Graph Approach for Fault Diagnosis of Nuclear Power Plant Sensors and Field Devices

Data driven multiple observer and causal graph approach to fault detection and isolation is developed for nuclear power plant sensors and actuators. It can be integrated into the advanced instrumentation and control system for the next generation nuclear power plants. The developed approach is based on analytical redundancy principle of fault diagnosis. Some analytical models are built to generate the residuals between measured values and expected values. Any significant residuals are used for fault detection and the residual patterns are analyzed for fault isolation. Advanced data driven modeling methods such as Principal Component Analysis and Adaptive Network Fuzzy Inference System are used to achieve on-line accurate and consistent models. As compared with most current data-driven modeling, it is emphasized that the best choice of model structure should be obtained from physical study on a system. Multiple observer approach realizes strong fault isolation through designing appropriate residual structures. Even if one of the residuals is corrupted, the approach is able to indicate an unknown fault instead of a misleading fault. Multiple observers are designed through making full use of the redundant relationships implied in a process when predicting one variable. Data-driven causal graph is developed as a generic approach to fault diagnosis for nuclear power plants where limited fault information is available. It has the potential of combining the reasoning capability of qualitative diagnostic method and the strength of quantitative diagnostic method in fault resolution. A data-driven causal graph consists of individual nodes representing plant variables connected with adaptive quantitative models. With the causal graph, fault detection is fulfilled by monitoring the residual of each model. Fault isolation is achieved by testing the possible assumptions involved in each model. Conservatism is implied in the approach since a faulty sensor or a fault actuator signal is isolated only when their reconstructions can fully explain all the abnormal behavior of the system. The developed approaches have been applied to nuclear steam generator system of a pressurized water reactor and a simulation code has been developed to show its performance. The results show that both single and dual sensor faults and actuator faults can be detected and isolated correctly independent of fault magnitudes and initial power level during early fault transient