Condition monitoring of an advanced gas-cooled nuclear reactor core

A critical component of an advanced gas-cooled reactor station is the graphite core. As a station ages, the graphite bricks that comprise the core can distort and may eventually crack. Since the core cannot be replaced, the core integrity ultimately determines the station life. Monitoring these distortions is usually restricted to the routine outages, which occur every few years, as this is the only time that the reactor core can be accessed by external sensing equipment. This paper presents a monitoring module based on model-based techniques using measurements obtained during the refuelling process. A fault detection and isolation filter based on unknown input observer techniques is developed. The role of this filter is to estimate the friction force produced by the interaction between the wall of the fuel channel and the fuel assembly supporting brushes. This allows an estimate to be made of the shape of the graphite bricks that comprise the core and, therefore, to monitor any distortion on them

Robust fault diagnosis for an exothermic semi-batch polymerization reactor under open-loop

An independent radial basis function neural network (RBFNN) is developed and employed here for an online diagnosis of actuator and sensor faults. In this research, a robust fault detection and isolation scheme is developed for an open-loop exothermic semi-batch polymerization reactor described by Chylla–Haase. The independent RBFNN is employed here for online diagnosis of faults when the system is subjected to system uncertainties and disturbances. Two different techniques to employ RBFNNs are investigated. Firstly, an independent neural network (NN) is used to model the reactor dynamics and generate residuals. Secondly, an additional RBFNN is developed as a classifier to isolate faults from the generated residuals. Three sensor faults and one actuator fault are simulated on the reactor. Moreover, many practical disturbances and system uncertainties, such as monomer feed rate, fouling factor, impurity factor, ambient temperature and measurement noise, are modelled. The simulation results are presented to illustrate the effectiveness and robustness of the proposed method

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

Monitoring and Fault Diagnosis for Chylla-Haase Polymerization Reactor

The main objective of this research is to develop a fault detection and isolation (FDI) methodologies for Cylla-Haase polymerization reactor, and implement the developed methods to the nonlinear simulation model of the proposed reactor to evaluate the effectiveness of FDI methods. The first part of this research focus of this chapter is to understand the nonlinear dynamic behaviour of the Chylla-Haase polymerization reactor. In this part, the mathematical model of the proposed reactor is described. The Simulink model of the proposed reactor is set up using Simulink/MATLAB. The design of Simulink model is developed based on a set of ordinary differential equations that describe the dynamic behaviour of the proposed polymerization reactor. An independent radial basis function neural networks (RBFNN) are developed and employed here for an on-line diagnosis of actuator and sensor faults. In this research, a robust fault detection and isolation (FDI) scheme is developed for open-loop exothermic semi-batch polymerization reactor described by Chylla-Haase. The independent (RBFNN) is employed here when the system is subjected to system uncertainties and disturbances. Two different techniques to employ RBF neural networks are investigated. Firstly, an independent neural network is used to model the reactor dynamics and generate residuals. Secondly, an additional RBF neural network is developed as a classifier to isolate faults from the generated residuals. In the third part of this research, a robust fault detection and isolation (FDI) scheme is developed to monitor the Chylla-Haase polymerization reactor, when it is under the cascade PI control. This part is really challenging task as the controller output cannot be designed when the reactor is under closed-loop control, and the control action will correct small changes of the states caused by faults. The proposed FDI strategy employed a radial basis function neural network (RBFNN) in an independent mode to model the process dynamics, and using the weighted sum-squared prediction error as the residual. The Recursive Orthogonal Least Squares algorithm (ROLS) is employed to train the model to overcome the training difficulty of the independent mode of the network. Then, another RBFNN is used as a fault classifier to isolate faults from different features involved in the residual vector. In this research, an independent MLP neural network is implemented here to generate residuals for detection task. And another RBF is applied for isolation task performing as a classifier. The fault diagnosis scheme is developed for a Chylla-Haase reactor under open-loop and closed-loop control system. The comparison between these two neural network architectures (MPL and RBF) are shown that RBF configuration trained by (RLS) algorithm have several advantages. The first one is greater efficiency in finding optimal weights for field strength prediction in complex dynamic systems. The RBF configuration is less complex network that results in faster convergence. The training algorithms (RLs and ROLS) that used for training RBFNN in chapter (4) and (5) have proven to be efficient, which results in significant faster computer time in comparison to back-propagation one. Another fault diagnosis (FD) scheme is developed in this research for an exothermic semi-batch polymerization reactor. The scheme includes two parts: the first part is to generate residual using an extended Kalman filter (EKF), and the second part is the decision making to report fault using a standardized hypothesis of statistical tests. The FD simulation results are presented to demonstrate the effectiveness of the proposed method. In the lase section of this research, a robust fault diagnosis scheme for abrupt and incipient faults in nonlinear dynamic system. A general framework is developed for model-based fault detection and diagnosis using on-line approximators and adaptation/learning schemes. In this framework, neural network models constitute an important class of on-line approximators. The changes in the system dynamics due to fault are modelled as nonlinear functions of the state, while the time profile of the fault is assumed to be exponentially developing. The changes in the system dynamics are monitored by an on-line approximation model, which is used for detecting the failures. A systematic procedure for constructing nonlinear estimation algorithm is developed, and a stable learning scheme is derived using Lyapunov theory. Simulation studies are used to illustrate the results and to show the effectiveness of the fault diagnosis methodology. Finally, the success of the proposed fault diagnosis methods illustrates the potential of the application of an independent RBFNN, an independent MLP, an Extended kalman filter and an adaptive nonlinear observer based FD, to chemical reactors

Continuous stirred tank reactor fault detection using higher degree Cubature Kalman filter

Continuous Stirred Tank Reactor (CSTR) plays a major role in chemical industries, it ensures the process of mixing reactants according to the attended specification to produce a specific output. It is a complex process that usually represent with nonlinear model for benchmarking. Any abnormality, disturbance and unusual condition can easily interrupt the operations, especially fault. And this problem need to detect and rectify as soon as possible. A good knowledge based fault detection using available model require a good error residual between the measurement and the estimated state. Kalman filter is an example of a good estimator, and has been exploited in many researches to detect fault. In this paper, Higher degree Cubature Kalman Filter (HDCKF) is proposed as a method for fault detection by estimation the current state. Cubature Kalman filter (CKF) is an extension of the Kalman filter with the main purpose is to estimate process and measurement state with high nonlinearities. It is based on spherical radial integration to estimate current state by generating cubature points with specific value. Conventional CKF use 3rd degree spherical and 3rd degree radial, here we implement Higher Degree CKF (HDCKF) to have better accuracy as compared to conventional CKF. High accuracy is required to ensure no false alarm is detected and furthermore good computational cost will improve its detection. Finally, a numerical example of CSTR fault detection using HDCKF is presented. Implementation of HDCKF for fault detection is compared with other filter to show effective results

Reaction rate reconstruction from biomass concentration measurement in bioreactors using modified second-order sliding mode algorithms

This paper deals with the estimation of unknown signals in bioreactors using sliding observers. Particular attention is drawn to estimate the specific growth rate of microorganisms from measurement of biomass concentration. In a recent article, notions of high-order sliding modes have been used to derive a growth rate observer for batch processes. In this paper we generalize and refine these preliminary results. We develop a new observer with a different error structure to cope with other types of processes. Furthermore, we show that these observers are equivalent, under coordinate transformations and time scaling, to the classical super-twisting differentiator algorithm, thus inheriting all its distinctive features. The new observers’ family achieves convergence to timevarying unknown signals in finite time, and presents the best attainable estimation error order in the presence of noise. In addition, the observers are robust to modeling and parameter uncertainties since they are based on minimal assumptions on bioprocess dynamics. In addition, they have interesting applications in fault detection and monitoring. The observers performance in batch, fed-batch and continuous bioreactors is assessed by experimental data obtained from the fermentation of Saccharomyces Cerevisiae on glucose.This work was supported by the National University of La Plata (Project 2012-2015), the Agency for the Promotion of Science and Technology ANPCyT (PICT2007-00535) and the National Research Council CONICET (PIP112-200801-01052) of Argentina; the Technical University of Valencia (PAID-02-09), the CICYT (DPI2005-01180) and AECID (A/024186/09) of Spain; and by the project FEDER of the European Union.De Battista, H.; Picó Marco, JA.; Garelli, F.; Navarro Herrero, JL. (2012). 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Modeling and fault tolerant control of an electro-hydraulic actuator

In the modern industry, electro-hydraulic actuators (EHAs) have been applied to various applications for precise position pressure/ force control tasks. However, operating EHAs under sensor faults is one of the critical challenges for the control engineers. For its enormous nonlinear characteristics, sensor fault could lead the catastrophic failure to the overall system or even put human life in danger. Thus in this paper, a study on mathematical modeling and fault tolerant control (FTC) of a typical EHA for tracking control under sensor-fault conditions has been carried out. In the proposed FTC system, the extended Kalman-Bucy unknown input observer (EKBUIO) -based robust sensor fault detection and identification (FDI) module estimates the system states and the time domain fault information. Once a fault is detected, the controller feedback is switched from the faulty sensor to the estimated output from the EKBUIO owing to mask the sensor fault swiftly and retains the system stability. Additionally, considering the tracking accuracy of the EHA system, an efficient brain emotional learning based intelligent controller (BELBIC) is suggested as the main control unit. Effectiveness of the proposed FTC architecture has been investigated by experimenting on a test bed using an EHA in sensor failure conditions

An Integrated Approach to Performance Monitoring and Fault Diagnosis of Nuclear Power Systems

In this dissertation an integrated framework of process performance monitoring and fault diagnosis was developed for nuclear power systems using robust data driven model based methods, which comprises thermal hydraulic simulation, data driven modeling, identification of model uncertainty, and robust residual generator design for fault detection and isolation. In the applications to nuclear power systems, on the one hand, historical data are often not able to characterize the relationships among process variables because operating setpoints may change and thermal fluid components such as steam generators and heat exchangers may experience degradation. On the other hand, first-principle models always have uncertainty and are often too complicated in terms of model structure to design residual generators for fault diagnosis. Therefore, a realistic fault diagnosis method needs to combine the strength of first principle models in modeling a wide range of anticipated operation conditions and the strength of data driven modeling in feature extraction. In the developed robust data driven model-based approach, the changes in operation conditions are simulated using the first principle models and the model uncertainty is extracted from plant operation data such that the fault effects on process variables can be decoupled from model uncertainty and normal operation changes. It was found that the developed robust fault diagnosis method was able to eliminate false alarms due to model uncertainty and deal with changes in operating conditions throughout the lifetime of nuclear power systems. Multiple methods of robust data driven model based fault diagnosis were developed in this dissertation. A complete procedure based on causal graph theory and data reconciliation method was developed to investigate the causal relationships and the quantitative sensitivities among variables so that sensor placement could be optimized for fault diagnosis in the design phase. Reconstruction based Principal Component Analysis (PCA) approach was applied to deal with both simple faults and complex faults for steady state diagnosis in the context of operation scheduling and maintenance management. A robust PCA model-based method was developed to distinguish the differences between fault effects and model uncertainties. In order to improve the sensitivity of fault detection, a hybrid PCA model based approach was developed to incorporate system knowledge into data driven modeling. Subspace identification was proposed to extract state space models from thermal hydraulic simulations and a robust dynamic residual generator design algorithm was developed for fault diagnosis for the purpose of fault tolerant control and extension to reactor startup and load following operation conditions. The developed robust dynamic residual generator design algorithm is unique in that explicit identification of model uncertainty is not necessary. Finally, it was demonstrated that the developed new methods for the IRIS Helical Coil Steam Generator (HCSG) system. A simulation model was first developed for this system. It was revealed through steady state simulation that the primary coolant temperature profile could be used to indicate the water inventory inside the HCSG tubes. The performance monitoring and fault diagnosis module was then developed to monitor sensor faults, flow distribution abnormality, and heat performance degradation for both steady state and dynamic operation conditions. This dissertation bridges the gap between the theoretical research on computational intelligence and the engineering design in performance monitoring and fault diagnosis for nuclear power systems. The new algorithms have the potential of being integrated into the Generation III and Generation IV nuclear reactor I&C design after they are tested on current nuclear power plants or Generation IV prototype reactors

Observer-based Fault Diagnosis: Applications to Exothermic Continuous Stirred Tank Reactors

For chemical engineering dynamic systems, there is an increasing demand for better process performance, high product quality, absolute reliability & safety, maximum cost efficiency and less environmental impact. Improved individual process components and advanced automatic control techniques have brought significant benefits to the chemical industry. However, fault-free operation of processes cannot be guaranteed. Timely fault diagnosis and proper management can help to avoid or at least minimize the undesirable consequences. There are many techniques for fault diagnosis, and observer-based methods have been widely studied and have proved to be efficient for fault diagnosis. The basic idea of an observer-based approach is to generate a specific residual signal which carries the information of specific faults, as well as the information of process disturbances, model uncertainties, other faults and measurement noises. For fault diagnosis, the residual should be sensitive to faults and insensitive to other unknown inputs. With this feature, faults can be easily detected and may be isolated and identified. This thesis applied an observer-based fault diagnosis method to three exothermic CSTR case studies. In order to improve the operational safety of exothermic CSTRs with risks of runaway reactions and explosion, fault diagnostic observers are built for fault detection, isolation and identification. For this purpose, different types of most common faults have been studied in different reaction systems. For each fault, a specific observer and the corresponding residual is built, which works as an indicator of that fault and is robust to other unknown inputs. For designing linear observers, the original nonlinear system is linearized at steady state, and the observer is designed based on the linearized system. However, in the simulations, the observer is tested on the nonlinear system instead of the linearized system. In addition, an efficient & effective general MATLAB program has been developed for fault diagnosis observer design. Extensive simulation studies have been performed to test the fault diagnostic observer on exothermic CSTRs. The results show that the proposed fault diagnosis scheme can be directly implemented and it works well for diagnosing faults in exothermic chemical reactors