Methods and Systems for Fault Diagnosis in Nuclear Power Plants

This research mainly deals with fault diagnosis in nuclear power plants (NPP), based on a framework that integrates contributions from fault scope identification, optimal sensor placement, sensor validation, equipment condition monitoring, and diagnostic reasoning based on pattern analysis. The research has a particular focus on applications where data collected from the existing SCADA (supervisory, control, and data acquisition) system is not sufficient for the fault diagnosis system. Specifically, the following methods and systems are developed. A sensor placement model is developed to guide optimal placement of sensors in NPPs. The model includes 1) a method to extract a quantitative fault-sensor incidence matrix for a system; 2) a fault diagnosability criterion based on the degree of singularities of the incidence matrix; and 3) procedures to place additional sensors to meet the diagnosability criterion. Usefulness of the proposed method is demonstrated on a nuclear power plant process control test facility (NPCTF). Experimental results show that three pairs of undiagnosable faults can be effectively distinguished with three additional sensors selected by the proposed model. A wireless sensor network (WSN) is designed and a prototype is implemented on the NPCTF. WSN is an effective tool to collect data for fault diagnosis, especially for systems where additional measurements are needed. The WSN has distributed data processing and information fusion for fault diagnosis. Experimental results on the NPCTF show that the WSN system can be used to diagnose all six fault scenarios considered for the system. A fault diagnosis method based on semi-supervised pattern classification is developed which requires significantly fewer training data than is typically required in existing fault diagnosis models. It is a promising tool for applications in NPPs, where it is usually difficult to obtain training data under fault conditions for a conventional fault diagnosis model. The proposed method has successfully diagnosed nine types of faults physically simulated on the NPCTF. For equipment condition monitoring, a modified S-transform (MST) algorithm is developed by using shaping functions, particularly sigmoid functions, to modify the window width of the existing standard S-transform. The MST can achieve superior time-frequency resolution for applications that involves non-stationary multi-modal signals, where classical methods may fail. Effectiveness of the proposed algorithm is demonstrated using a vibration test system as well as applications to detect a collapsed pipe support in the NPCTF. The experimental results show that by observing changes in time-frequency characteristics of vibration signals, one can effectively detect faults occurred in components of an industrial system. To ensure that a fault diagnosis system does not suffer from erroneous data, a fault detection and isolation (FDI) method based on kernel principal component analysis (KPCA) is extended for sensor validations, where sensor faults are detected and isolated from the reconstruction errors of a KPCA model. The method is validated using measurement data from a physical NPP. The NPCTF is designed and constructed in this research for experimental validations of fault diagnosis methods and systems. Faults can be physically simulated on the NPCTF. In addition, the NPCTF is designed to support systems based on different instrumentation and control technologies such as WSN and distributed control systems. The NPCTF has been successfully utilized to validate the algorithms and WSN system developed in this research. In a real world application, it is seldom the case that one single fault diagnostic scheme can meet all the requirements of a fault diagnostic system in a nuclear power. In fact, the values and performance of the diagnosis system can potentially be enhanced if some of the methods developed in this thesis can be integrated into a suite of diagnostic tools. In such an integrated system, WSN nodes can be used to collect additional data deemed necessary by sensor placement models. These data can be integrated with those from existing SCADA systems for more comprehensive fault diagnosis. An online performance monitoring system monitors the conditions of the equipment and provides key information for the tasks of condition-based maintenance. When a fault is detected, the measured data are subsequently acquired and analyzed by pattern classification models to identify the nature of the fault. By analyzing the symptoms of the fault, root causes of the fault can eventually be identified

Fifth Conference on Artificial Intelligence for Space Applications

The Fifth Conference on Artificial Intelligence for Space Applications brings together diverse technical and scientific work in order to help those who employ AI methods in space applications to identify common goals and to address issues of general interest in the AI community. Topics include the following: automation for Space Station; intelligent control, testing, and fault diagnosis; robotics and vision; planning and scheduling; simulation, modeling, and tutoring; development tools and automatic programming; knowledge representation and acquisition; and knowledge base/data base integration

Data fusion for system modeling, performance assessment and improvement

Due to rapid advancements in sensing and computation technology, multiple types of sensors have been embedded in various applications, on-line automatically collecting massive production information. Although this data-rich environment provides great opportunity for more effective process control, it also raises new research challenges on data analysis and decision making due to the complex data structures, such as heterogeneous data dependency, and large-volume and high-dimensional characteristics. This thesis contributes to the area of System Informatics and Control (SIAC) to develop systematic data fusion methodologies for effective quality control and performance improvement in complex systems. These advanced methodologies enable (1) a better handling of the rich data environment communicated by complex engineering systems, (2) a closer monitoring of the system status, and (3) a more accurate forecasting of future trends and behaviors. The research bridges the gaps in methodologies among advanced statistics, engineering domain knowledge and operation research. It also forms close linkage to various application areas such as manufacturing, health care, energy and service systems. This thesis started from investigating the optimal sensor system design and conducting multiple sensor data fusion analysis for process monitoring and diagnosis in different applications. In Chapter 2, we first studied the couplings or interactions between the optimal design of a sensor system in a Bayesian Network and quality management of a manufacturing system, which can improve cost-effectiveness and production yield by considering sensor cost, process change detection speed, and fault diagnosis accuracy in an integrated manner. An algorithm named “Best Allocation Subsets by Intelligent Search” (BASIS) with optimality proof is developed to obtain the optimal sensor allocation design at minimum cost under different user specified detection requirements. Chapter 3 extended this line of research by proposing a novel adaptive sensor allocation framework, which can greatly improve the monitoring and diagnosis capabilities of the previous method. A max-min criterion is developed to manage sensor reallocation and process change detection in an integrated manner. The methodology was tested and validated based on a hot forming process and a cap alignment process. Next in Chapter 4, we proposed a Scalable-Robust-Efficient Adaptive (SERA) sensor allocation strategy for online high-dimensional process monitoring in a general network. A monitoring scheme of using the sum of top-r local detection statistics is developed, which is scalable, effective and robust in detecting a wide range of possible shifts in all directions. This research provides a generic guideline for practitioners on determining (1) the appropriate sensor layout; (2) the “ON” and “OFF” states of different sensors; and (3) which part of the acquired data should be transmitted to and analyzed at the fusion center, when only limited resources are available. To improve the accuracy of remaining lifetime prediction, Chapter 5 proposed a data-level fusion methodology for degradation modeling and prognostics. When multiple sensors are available to measure the degradation mechanism of a same system, it becomes a high dimensional and challenging problem to determine which sensors to use and how to combine them together for better data analysis. To address this issue, we first defined two essential properties if present in a degradation signal, can enhance the effectiveness for prognostics. Then, we proposed a generic data-level fusion algorithm to construct a composite health index to achieve those two identified properties. The methodology was tested using the degradation signals of aircraft gas turbine engine, which demonstrated a much better prognostic result compared to relying solely on the data from an individual sensor. In summary, this thesis is the research drawing attention to the area of data fusion for effective employment of the underlying data gathering capabilities for system modeling, performance assessment and improvement. The fundamental data fusion methodologies are developed and further applied to various applications, which can facilitate resources planning, real-time monitoring, diagnosis and prognostics.Ph.D

Prognostics and health aware model predictive control of wind turbines

Wind turbines components are subject to considerable stresses and fatigue due to extreme environmental conditions to which they are exposed, especially those located offshore. Also, the most common faults present in wind turbine components have been investigated for years by the research community and that has led to propose a fault diagnosis and fault tolerant control wind turbine benchmark which include a set of faults that affect the sensors and actuators of several wind turbine components. This thesis presents some contributions to the fields of fault diagnosis, fault-tolerant control, prognostics and its integration with wind turbine control which leads to proposing a control approach called health-aware model predictive control (HAMPC). The contributions are summarized below: - Model-based fault diagnosis: to perform fault detection and isolation interval-based observers together with a set of analytical redundant relations (ARRs) are obtained based on a structural analysis and the fault signature matrix that relates the ARRs with the faults. - Fault tolerant control: it is proposed a fault tolerant control scheme that integrates fault detection and an algorithm for fault accommodation. The scheme has the objective to avoid the increment of blades and tower loads when a fault in the rotor azimuth angle sensor occurs using the individual pitch control technique (IPC). - Wind turbine blades fatigue prognostics and degradation: fatigue is assessed using the rainflow counting algorithm which is used to estimate the accumulated damage and for degradation, it is used a stiffness degradation model of blades material which is used to make predictions of remaining useful life (RUL). - Wind turbines health control: the module for the health of the system based on fatigue damage estimation and RUL predictions is integrated with model predictive control (MPC) leading to the proposed control approach (HAMPC). The contributions presented in this thesis have been validated on a wind turbine study case that uses a 5MW wind turbine reference model implemented in a high fidelity wind turbine simulator (FAST).Els components dels aerogeneradors estan sotmesos a considerable estrès i fatiga, degut a les condicions ambientals extremes a les quals estan exposats, especialment els localitzats en alta mar. Per aquest motiu, al comunitat científica durant els últims anys ha investigat les averies més comunes presents en els aerogeneradors, fet que ha portat a proposar un cas d'estudi de diagnosi i control tolerant de fallades que inclou un conjunt de fallades que afecten a diversos components dels aerogeneradors. Aquesta tesi presenta algunes contribucions en els camps de la diagnosi de fallades, el control tolerant de fallades i la prognosi, així com la seva integració amb el control d'aerogeneradors, fet que ha portat a proposar una tècnica de control anomenada control predictiu basada en models conscients de la salut del sistema (HAMPC). Concretament les aportacions es poden resumir en: - Diagnosi de fallades basada en models: per a la detecció s'utilitzen observadors intervalars i l'aïllament de la fallada es fa en base el conjunt d'ARRs obtinguts de l'anàlisi estructural i de la matriu de signatures de fallades que relaciona les ARRs amb les fallades. - Control tolerant de fallades: es proposa un esquema de control tolerant a fallades que integra la detecció de fallades i algoritme d'acomodació de fallades, i té per objectiu evitar l'augment de càrregues en la pala i la torre quan es produeix una fallada en el sensor azimuth quan es fa un control individual de la inclinació de les pales (IPC). - Prognosi de la fatiga i la degradació de les pales: la fatiga s'avalua amb un algorisme denominat "rainflow counting" amb el qual es fa estimació del dany acumulat i per a la degradació es fa servir un model de degradació de la rigidesa del material amb el qual es fan prediccions de la vida útil restant (RUL). - Control de la salut d'aerogeneradors: s'ha integrat la gestió de la salut del sistema basat en danys per fatiga o prediccions de RUL amb control predictiu basat en models (MPC) donant lloc al control que anomenem HAMPC. Les contribucions presentades en aquesta tesi han sigut validades en un cas d'estudi d'aerogeneradors basat en un aerogenerador de referència de 5MW de potència implementat en el simulador d'aerogeneradors d'alta fidelitat conegut amb el nom de FAST.Postprint (published version

Architecting Networked Engineering Systems

The primary goal in this dissertation is to create a new knowledge, make a transformative influence in the design of networked engineering systems adaptable to ambitious market demands, and to accommodate the Industry 4.0 design principles based on the philosophy that design is fundamentally a decision making process. The principal motivation in this dissertation is to establish a computational framework that is suitable for the design of low-cost and high-quality networked engineering systems adaptable to ambitious market demands in the context of Industry 4.0. Dynamic and ambitious global market demands make it necessary for competitive enterprises to have low-cost manufacturing processes and high-quality products. Smart manufacturing is increasingly being adopted by companies to respond to changes in the market. These smart manufacturing systems must be adaptable to dynamic changes and respond to unexpected disturbances, and uncertainty. Accordingly, a decision-based design computational framework, Design for Dynamic Management (DFDM), is proposed as a support to flexible, operable and rapidly configurable manufacturing processes. DFDM has three critical components: adaptable and concurrent design, operability analysis and reconfiguration strategies. Adaptable and concurrent design methods offer flexibility in selection of design parameters and the concurrent design of the mechanical and control systems. Operability analysis is used to determine the functionality of the system undergoing dynamic change. Reconfiguration strategies allow multiple configurations of elements in the system. It is expected that proposed computational framework results in next generation of networked engineering systems, where tools and sensors communicate with each other via the Internet of Things (IoT), sensors data would be used to create enriched digital system models, adaptable to fast-changing market requirements, which can produce higher quality products over a longer lifetime and at a lower cost. The computational framework and models proposed in this dissertation are applicable in system design, and/or product-service system design. This dissertation is a fundamental research and a way forward is DFDM transition to the industry through decision-based design platform. Decision-based design platform is a step toward new frontiers, Cyber-Physical-Social System Design, Manufacturing, and Services, contributing to further digitization

Understanding the role of sensor optimisation in complex systems

Complex systems involve monitoring, assessing, and predicting the health of various systems within an integrated vehicle health management (IVHM) system or a larger system. Health management applications rely on sensors that generate useful information about the health condition of the assets; thus, optimising the sensor network quality while considering specific constraints is the first step in assessing the condition of assets. The optimisation problem in sensor networks involves considering trade-offs between different performance metrics. This review paper provides a comprehensive guideline for practitioners in the field of sensor optimisation for complex systems. It introduces versatile multi-perspective cost functions for different aspects of sensor optimisation, including selection, placement, data processing and operation. A taxonomy and concept map of the field are defined as valuable navigation tools in this vast field. Optimisation techniques and quantification approaches of the cost functions are discussed, emphasising their adaptability to tailor to specific application requirements. As a pioneering contribution, all the relevant literature is gathered and classified here to further improve the understanding of optimal sensor networks from an information-gain perspective

Smart Manufacturing

This book is a collection of 11 articles that are published in the corresponding Machines Special Issue “Smart Manufacturing”. It represents the quality, breadth and depth of the most updated study in smart manufacturing (SM); in particular, digital technologies are deployed to enhance system smartness by (1) empowering physical resources in production, (2) utilizing virtual and dynamic assets over the Internet to expand system capabilities, (3) supporting data-driven decision-making activities at various domains and levels of businesses, or (4) reconfiguring systems to adapt to changes and uncertainties. System smartness can be evaluated by one or a combination of performance metrics such as degree of automation, cost-effectiveness, leanness, robustness, flexibility, adaptability, sustainability, and resilience. This book features, firstly, the concepts digital triad (DT-II) and Internet of digital triad things (IoDTT), proposed to deal with the complexity, dynamics, and scalability of complex systems simultaneously. This book also features a comprehensive survey of the applications of digital technologies in space instruments; a systematic literature search method is used to investigate the impact of product design and innovation on the development of space instruments. In addition, the survey provides important information and critical considerations for using cutting edge digital technologies in designing and manufacturing space instruments

Large space structures and systems in the space station era: A bibliography with indexes

Bibliographies and abstracts are listed for 1219 reports, articles, and other documents introduced into the NASA scientific and technical information system between July 1, 1990 and December 31, 1990. The purpose is to provide helpful information to the researcher, manager, and designer in technology development and mission design according to system, interactive analysis and design, structural and thermal analysis and design, structural concepts and control systems, electronics, advanced materials, assembly concepts, propulsion, and solar power satellite systems