Reference model based maintenance of control system performance for industrial processes

In the last decade, fault tolerant controls (FTC) have enjoyed tremendous success to effectively accommodate defects in sensors, actuators, or plants. However, little of them considered what should be done once a control system performance is degraded during the operation. The aim of this paper is to maintain the performance of a control system at an acceptable level based on a pre-defined reference model. A maintenance approach is proposed and experimented in this paper. The method is to insert a compensator into the faulty control system and make the compensator and the faulty open loop system working together to track the pre-defined reference model. The proposed method is illustrated by reference to a mini process rig and shows the potential to industrial processes

Reference Model Based Maintenance of Control System Performance for Industrial Processes

In the last decade, fault tolerant controls (FTC) have enjoyed tremendous success to effectively accommodate defects in sensors, actuators, or plants. However, little of them considered what should be done once a control system performance is degraded during the operation. The aim of this paper is to maintain the performance of a control system at an acceptable level based on a pre-defined reference model. A maintenance approach is proposed and experimented in this paper. The method is to insert a compensator into the faulty control system and make the compensator and the faulty open loop system working together to track the pre-defined reference model. The proposed method is illustrated by reference to a mini process rig and shows the potential to industrial processes

Advanced Techniques for Assets Maintenance Management

16th IFAC Symposium on Information Control Problems in Manufacturing INCOM 2018 Bergamo, Italy, 11–13 June 2018. Edited by Marco Macchi, László Monostori, Roberto PintoThe aim of this paper is to remark the importance of new and advanced techniques supporting decision making in different business processes for maintenance and assets management, as well as the basic need of adopting a certain management framework with a clear processes map and the corresponding IT supporting systems. Framework processes and systems will be the key fundamental enablers for success and for continuous improvement. The suggested framework will help to define and improve business policies and work procedures for the assets operation and maintenance along their life cycle. The following sections present some achievements on this focus, proposing finally possible future lines for a research agenda within this field of assets management

Adaptive Signal Processing Strategy for a Wind Farm System Fault Accommodation

In order to improve the availability of offshore wind farms, thus avoiding unplanned operation and maintenance costs, which can be high for offshore installations, the accommodation of faults in their earlier occurrence is fundamental. This paper addresses the design of an active fault tolerant control scheme that is applied to a wind park benchmark of nine wind turbines, based on their nonlinear models, as well as the wind and interactions between the wind turbines in the wind farm. Note that, due to the structure of the system and its control strategy, it can be considered as a fault tolerant cooperative control problem of an autonomous plant. The controller accommodation scheme provides the on-line estimate of the fault signals generated by nonlinear filters exploiting the nonlinear geometric approach to obtain estimates decoupled from both model uncertainty and the interactions among the turbines. This paper proposes also a data-driven approach to provide these disturbance terms in analytical forms, which are subsequently used for designing the nonlinear filters for fault estimation. This feature of the work, followed by the simpler solution relying on a data-driven approach, can represent the key point when on-line implementations are considered for a viable application of the proposed scheme

Data-driven Soft Sensors in the Process Industry

In the last two decades Soft Sensors established themselves as a valuable alternative to the traditional means for the acquisition of critical process variables, process monitoring and other tasks which are related to process control. This paper discusses characteristics of the process industry data which are critical for the development of data-driven Soft Sensors. These characteristics are common to a large number of process industry fields, like the chemical industry, bioprocess industry, steel industry, etc. The focus of this work is put on the data-driven Soft Sensors because of their growing popularity, already demonstrated usefulness and huge, though yet not completely realised, potential. A comprehensive selection of case studies covering the three most important Soft Sensor application fields, a general introduction to the most popular Soft Sensor modelling techniques as well as a discussion of some open issues in the Soft Sensor development and maintenance and their possible solutions are the main contributions of this work

A framework for effective management of condition based maintenance programs in the context of industrial development of E-Maintenance strategies

CBM (Condition Based Maintenance) solutions are increasingly present in industrial systems due to two main circumstances: rapid evolution, without precedents, in the capture and analysis of data and significant cost reduction of supporting technologies. CBM programs in industrial systems can become extremely complex, especially when considering the effective introduction of new capabilities provided by PHM (Prognostics and Health Management) and E-maintenance disciplines. In this scenario, any CBM solution involves the management of numerous technical aspects, that the maintenance manager needs to understand, in order to be implemented properly and effectively, according to the company’s strategy. This paper provides a comprehensive representation of the key components of a generic CBM solution, this is presented using a framework or supporting structure for an effective management of the CBM programs. The concept “symptom of failure”, its corresponding analysis techniques (introduced by ISO 13379-1 and linked with RCM/FMEA analysis), and other international standard for CBM open-software application development (for instance, ISO 13374 and OSA-CBM), are used in the paper for the development of the framework. An original template has been developed, adopting the formal structure of RCM analysis templates, to integrate the information of the PHM techniques used to capture the failure mode behaviour and to manage maintenance. Finally, a case study describes the framework using the referred template.Gobierno de Andalucía P11-TEP-7303 M

Continuous maintenance and the future – Foundations and technological challenges

High value and long life products require continuous maintenance throughout their life cycle to achieve required performance with optimum through-life cost. This paper presents foundations and technologies required to offer the maintenance service. Component and system level degradation science, assessment and modelling along with life cycle ‘big data’ analytics are the two most important knowledge and skill base required for the continuous maintenance. Advanced computing and visualisation technologies will improve efficiency of the maintenance and reduce through-life cost of the product. Future of continuous maintenance within the Industry 4.0 context also identifies the role of IoT, standards and cyber security

On the role of Prognostics and Health Management in advanced maintenance systems

The advanced use of the Information and Communication Technologies is evolving the way that systems are managed and maintained. A great number of techniques and methods have emerged in the light of these advances allowing to have an accurate and knowledge about the systems’ condition evolution and remaining useful life. The advances are recognized as outcomes of an innovative discipline, nowadays discussed under the term of Prognostics and Health Management (PHM). In order to analyze how maintenance will change by using PHM, a conceptual model is proposed built upon three views. The model highlights: (i) how PHM may impact the definition of maintenance policies; (ii) how PHM fits within the Condition Based Maintenance (CBM) and (iii) how PHM can be integrated into Reliability Centered Maintenance (RCM) programs. The conceptual model is the research finding of this review note and helps to discuss the role of PHM in advanced maintenance systems.EU Framework Programme Horizon 2020, 645733 - Sustain-Owner - H2020-MSCA-RISE-201