In this work, we have developed a reduced order model relevant for fault diagnosis and control. This model is combined with a generalized likelihood ratio (GLR) method and integrated with fault tolerant control schemes developed earlier. Simulation studies of an ideal binary distillation column show that the use of reduced order model improves the diagnostic performance thereby leading to improved fault tolerance. Furthermore, the proposed strategy is also computational more efficient. In inferential control, such as the use of temperature measurements to infer product compositions, the proposed fault tolerant control scheme performs better than the conventional control scheme when various soft faults occur. © 2008 Canadian Society for Chemical Engineering.

Shankar Narasimhan

Department Of Chemical Engineering

Seema Manuja

Distillation

Distillation columns

Electric fault currents

Joints (structural components)

Mathematical models

Maximum likelihood estimation

Quality assurance

reliability

temperature measurement

Binary distillation columns

CONVENTIONAL CONTROLS

DIAGNOSTIC PERFORMANCES

Efficient

Fault diagnosis

Fault tolerant control

FAULT TOLERANT CONTROLS

Generalized likelihood ratios

GLR method

Inferential controls

Model reduction

PRODUCT COMPOSITIONS

Reduced order models

Simulation studies

Soft faults

FAULT TOLERANCE

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IIT Madras has been ranked as the top engineering institute in India for four years in a row by the National Institutional Ranking Framework of the MHRD

It currently offers undergraduate, postgraduate and research degrees across 16 disciplines in Engineering, Sciences, Humanities and Management. About 596 faculty belonging to science and engineering departments and centres of the Institute are engaged in teaching, research and industrial consultancy.

IIT Madras

Canadian Journal of Chemical Engineering

Simultaneous occurrence of gross errors (outliers/biases/drifts) in the measured signals, and drifting disturbances/parameter variations affecting the system dynamics can lead to biased state estimates, and, in turn, can lead to deterioration in the performance of model-based monitoring and control schemes. In this work, robust recursive and moving window based Bayesian state and parameter estimators are developed that are robust w.r.t. gross errors in the measurements and can simultaneously estimate non-additive unmeasured disturbance/parameter variations. Using Bayes’ rule, the update step of Kalman filter (KF) is recast as an optimization problem. The optimization is then modified by replacing the likelihood term in the objective function with cost function defined by an M-estimator. The M-estimators considered in this work are Huber's Fair function and Hampel's redescending estimator. The reformulated KF is then used as a basis for reformulating extended Kalman filter (EKF). This re-formulated EKF is then used for developing robust simultaneous state and parameter estimation schemes. In particular, a robust version of recently proposed moving window based state and parameter estimator [1] has been developed. The resulting formulation can be viewed as a hybrid approach, in which the gross errors in the measurements are dealt with in a passive manner, with an active elimination of model plant mismatch by estimating unmeasured disturbance/parameter variations simultaneously. The efficacy of the proposed robust state and parameter estimators is demonstrated by conducting simulation studies and experimental studies. Analysis of the simulation and experimental results reveal that the proposed robust recursive and moving window based state and parameter estimators significantly reduce or completely nullify the effect of gross errors on the state estimates while simultaneously estimating drifting unmeasured disturbances/parameters. The simulation study also underscores the importance of simultaneous estimation of unmeasured disturbances/parameters while achieving robustness using the M-estimators. Moreover, Hampel's redescending estimator is found to be a better choice of M-estimator than the popular Huber's Fair function, as the redescending estimator can completely nullify the effect of gross errors on the state and parameter estimates. © 2018 Elsevier Ltd

Journal of Process Control

Development of robust extended Kalman filter and moving window estimator for simultaneous state and parameter/disturbance estimation

Many chemical processes exhibit highly nonlinear dynamic behavior when operated over a wide operating range. The fault diagnosis schemes based on a linear perturbation model often prove to be inadequate, with regard to addressing fault diagnosis problems in such systems. In this work, a novel multiple-operating-regimes-based technique is proposed for performing online fault diagnosis in nonlinear systems. A Bayesian approach is used to identify the combination of linear perturbation models in different operating regimes that best-represents the plant dynamics at the current operating point. Nonlinear versions of the generalized likelihood ratio (GLR) method that use multiple linear models for fault identification are proposed. The proposed multimodel based fault diagnosis approaches are computationally efficient and exploit the linearity of each submodel. To arrest the performance degradation caused by the occurrence of faults, the information provided by the fault diagnosis component is then used for online fault accommodation. The efficacy of the proposed diagnosis schemes is demonstrated by conducting simulation studies on two benchmark continuously stirred tank reactor (CSTR) systems and a high-purity binary distillation column system. Analysis of the simulation results reveals that the proposed multimodel Kalman filter-based fault diagnosis schemes outperform the linear GLR method when a nonlinear process is in a transient state over a wide operating range. © 2008 American Chemical Society.

Industrial and Engineering Chemistry Research

Online fault diagnosis in nonlinear systems using the multiple operating regime approach

Model predictive control (MPC) schemes are typically developed under the assumption that the sensors and actuators are free from faults. Attempts to develop fault-tolerant MPC schemes have mainly focused on dealing with hard faults, such as sensor or actuator failures, process leaks, etc. However, soft faults such as biases or drifts in sensors or actuators are more frequently encountered in the process industry. Occurrences of such faults can lead to degradation in the closed loop performance of the MPC controller. Since MPC controllers are typically used to control key operations in a chemical plant, this can have an impact on safety and productivity of the entire plant. The conventional approach to dealing with such soft faults in MPC formulations is through the introduction of additional artificial states to the model. The main limitation of this approach is that number of artificial extra states introduced cannot exceed the number of measurements. This implies that it is necessary to have a priori knowledge of which subset of faults are most likely to occur. In this paper, an active on-line fault-tolerant model predictive control (FTMPC) scheme is proposed by integrating state space formulation of MPC with the fault detection and identification (FDI) method based on generalized likelihood ratios. The fact that both these schemes use a Kalman filter as their basis facilitates tight integration of these two components. The main difference between the conventional MPC formulation and FTMPC formulation is that the bias corrections to the model are made as and when necessary and at qualified locations identified by the FDI component. The FTMPC eliminates offset between the true values and set points of controlled variables in the presence of a variety of faults while conventional MPC does not. Also, the true values of state variables, manipulated inputs, and measured variables are maintained within their imposed bounds in FTMPC, while in conventional MPC, these may be violated when soft faults occur. These advantages of the proposed scheme are demonstrated using simulation studies on a CSTR process and experimental studies conducted on the temperature control of a coupled two tank heater system. © 2005 American Chemical Society.

Integrating model based fault diagnosis with model predictive control

Coventional control schemes are developed under the assumption that the sensors and actuators are free from faults. However, the occurrence of faults will cause degradation in the closed-loop performance and also will have an impact on safety, productivity, and plant economy. In the present work, we have proposed a fault-tolerant control scheme (FTCS) by integrating a fault detection and identification (FDI) technique with conventional control. The principal component of our proposed FTCS is a compensation strategy (supervisory system) which uses the information provided by the FDI to appropriately modify the controller as well as the model used in FDI. This allows online application of the FTCS without causing significant degradation in the closed-loop performance due to the occurrences of biases in sensors and actuators or due to changes in unmeasured disturbance variables and due to moderate change in process parameters. Through stochastic simulation studies of a continuous stirred tank reactor process, we demonstrate that our proposed FTCS leads to significant improvement in the closed-loop performance in comparison to a conventional control scheme, especially as the fault magnitude increases. The proposed compensation scheme also allows identification of multiple faults that occur sequentially in time and is also found to be robust with respect to moderate plant-model mismatch.

A supervisory approach to fault-tolerant control of linear multivariable systems

Model Reduction for Control System Design Communications and Control Engineering

Methods for Model Reduction

IFAC Proceedings Volumes

Fault-Tolerant Control: The 1997 Situation

AIChE Journal

Output estimation using multiple secondary measurements: High-purity distillation

Fault diagnosis and fault tolerant control using reduced order models

Journal	Canadian Journal of Chemical Engineering
ISSN	00084034
Open Access	No