With the continuous increase in complexity and expense of industrial systems, there is less tolerance for performance degradation, productivity decrease, and safety hazards, which greatly necessitates to detect and identify any kinds of potential abnormalities and faults as early as possible and implement real-time fault-tolerant operation for minimizing performance degradation and avoiding dangerous situations. During the last four decades, fruitful results have been reported about fault diagnosis and fault-tolerant control methods and their applications in a variety of engineering systems. The three-part survey paper aims to give a comprehensive review of real-time fault diagnosis and fault-tolerant control, with particular attention on the results reported in the last decade. In this paper, fault diagnosis approaches and their applications are comprehensively reviewed from model- and signal-based perspectives, respectively.

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A Survey of Fault Diagnosis and Fault-Tolerant Techniques—Part I: Fault Diagnosis With Model-Based and Signal-Based Approaches

Recently, to ensure the reliability and safety of modern large-scale industrial processes, data-driven methods have been receiving considerably increasing attention, particularly for the purpose of process monitoring. However, great challenges are also met under different real operating conditions by using the basic data-driven methods. In this paper, widely applied data-driven methodologies suggested in the literature for process monitoring and fault diagnosis are surveyed from the application point of view. The major task of this paper is to sketch a basic data-driven design framework with necessary modifications under various industrial operating conditions, aiming to offer a reference for industrial process monitoring on large-scale industrial processes.

A Review on Basic Data-Driven Approaches for Industrial Process Monitoring

This review paper is to give a full picture of fault detection and diagnosis (FDD) in complex systems from the perspective of data processing. As a matter of fact, an FDD system is a data-processing system on the basis of information redundancy, in which the data and human's understanding of the data are two fundamental elements. Human's understanding may be an explicit input-output model representing the relationship among the system's variables. It may also be represented as knowledge implicitly (e.g., the connection weights of a neural network). Therefore, FDD is done through some kind of modeling, signal processing, and intelligence computation. In this paper, a variety of FDD techniques are reviewed within the unified data-processing framework to give a full picture of FDD and achieve a new level of understanding. According to the types of data and how the data are processed, the FDD methods are classified into three categories: model-based online data-driven methods, signal-based methods, and knowledge-based history data-driven methods. An outlook to the possible evolution of FDD in industrial automation, including the hybrid FDD and the emerging networked FDD, are also presented to reveal the future development direction in this field.

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From Model, Signal to Knowledge: A Data-Driven Perspective of Fault Detection and Diagnosis

Low grade thermal energy sources and uses from the process industry in the UK

In this paper, a data-driven scheme of key performance indicator (KPI) prediction and diagnosis is developed for complex industrial processes. For static processes, a KPI prediction and diagnosis approach is proposed in order to improve the prediction performance. In comparison with the standard partial least squares (PLS) method, the alternative approach significantly simplifies the computation procedure. By means of a data-driven realization of the so-called left coprime factorization (LCF) of a process, efficient KPI prediction, and diagnosis algorithms are developed for dynamic processes, respectively, with and without measurable KPIs. The proposed KPI prediction and diagnosis scheme is finally applied to an industrial hot strip mill, and the results demonstrate the effectiveness of the proposed scheme.

A Novel Scheme for Key Performance Indicator Prediction and Diagnosis With Application to an Industrial Hot Strip Mill

In this study, a novel identification technique, that is high-gain observer-based identification approach, is proposed for systems with bounded process and measurement noises. For system parameters with abnormal changes, an adaptive change detection and parameter identification algorithm is next presented. The presented technique and algorithm are finally applied to the parameter identification of the gas turbine engine by using the recorded input data from the engine test-bed. The identified parameters and the response curves are desirable. The simulations have proved the effectiveness of the proposed procedure compared with the previous identification approach.

Novel Parameter Identification by Using a High-Gain Observer With Application to a Gas Turbine Engine

This study is motivated by the onboard fault detection of gas turbine engines (GTEs), where the computation resources are limited and the disturbance is assumed to be band-limited. A fast Fourier transformation (FFT)-based disturbance frequency estimation approach is proposed and performance indexes are improved by integrating such frequency information. Furthermore, in the left eigenvector assignment, both eigenvalues and free parameters are optimized. As illustrated in the application to the actuator fault detection of a GTE, significant improvements are achieved compared to the existing methods. By combining the frequency estimation and eigenvalue optimization, the main contribution of the paper is the reduction of the computation complexity and the avoidance of the local optimal solution due to fixed eigenvalues.

Disturbance Attenuation in Fault Detection of Gas Turbine Engines: A Discrete Robust Observer Design

This technical note analyzes the estimation delay in a high gain observer, where the state estimates may lag behind the actual states due to the observer's non-zero phase response. The technical note proves that, for a slowly time-varying system subject to bounded noises, the estimation delay depends on the observer gain, but is independent of the variations of system parameters. Rather than estimating the delay, a novel method is proposed to calculate the delay from the observer's phase response. In terms of system identification, the delay is compensated by aligning other measurements with the lagged estimate so that they have the same lag. The simulation results of an aero engine model show significant improvements in estimation. On one hand, the proposed approach improves the estimation accuracy, and on the other hand, it removes the assumption of zero delay and gives a new insight into the high-gain observer design.

Timofei Breikin

Papers

Novel Parameter Identification by Using a High-Gain Observer With Application to a Gas Turbine Engine

Disturbance Attenuation in Fault Detection of Gas Turbine Engines: A Discrete Robust Observer Design

High-Gain Observer-Based Estimation of Parameter Variations With Delay Alignment

Modelling and Fault Diagnosis of Stator Inter-Turn Short Circuit in Doubly Fed Induction Generators

Sequential modelling of thermal energy: New potential for energy optimisation in papermaking