Fault simulator and detection for a process control valve

Timo Manninen

Fault simulator and detection for a process control valve

Julkaisun otsikon käännös: Vikasimulaattori ja vikojen havaitseminen prosessin säätöventtiilistä

Timo Manninen

Tutkimustuotos: Doctoral Thesis › Monograph

Abstrakti

Tässä työssä esitellään vikasimulaattori ja vikojen diagnosointimenetelmä pneumaattiselle prosessin säätöventtiilille. Vikasimulaattoria varten säätöventtiili on mallinnettu ja sen epälineaarisuudet on identifioitu estimoitujen parametrien avulla. Lisäksi mallit on verifioitu laboratoriomittausten avulla ja mallinnusvirheen on todettu olevan riittävän pieni vikasimulaatioiden suorittamiseen. Joitakin säätöventtiilivikoja on simuloitu simulaattorissa ja niiden vaikutusta on analysoitu virtauksen säätöpiiriin sisäisiin muuttujiin ja säätöpiirin suorituskykyyn. Esiteltyä vikasimulaattoria voidaan käyttää, niin vikadiagnoosimenetelmien, kuin robustin säädönkin tutkimukseen. Vikasimulaattorissa tehtyjen simulointien perusteella on mahdollista diagnosoida kaikki simuloidut viat ennenkuin ne vaikuttavat merkittävästi virtauksen säätöpiirin suorituskykyyn. Tämä diagnoosi voidaan tehdä tässä työssä esitellyllä menetelmällä, joka tarvitsee vain vähän laskentatehoa ja jossa diagnosointi tapahtuu prosessia häiritsemättä (on-line). Näinollen menetelmä voidaan toteuttaa älykkääseen venttiilinohjaimeen. Esitelty vikadiagnoosimenetelmä perustuu havaintoon, jossa vikaa lähin systeemin sisäinen muuttuja reagoi ja kompensoi vikaa takaisinkytketyssä säätöjärjestelmässä. Tämä johtaa myös siihen, että kaikkien vikaa edeltävien sisäisten muuttujien toimintapiste muuttuu vian seurauksena. Kun nämä toimintapistemuutoset voidaan havaita, voidaan myös systeemiin kohdistuvat viat diagnosoida. Esiteltyä menetelmää voidaan soveltaa kaikissa takaisinkytkettyä säätöä käyttävissä mekatronisissa järjestelmissä. Tämä esitelty menetelmä on verifioitu vikasimulaattorissa ja laboratoriossa koesarjoilla ja se pystyi diagnosoimaan kaikki testatut vikatapaukset.

Julkaisun otsikon käännös	Vikasimulaattori ja vikojen havaitseminen prosessin säätöventtiilistä
Alkuperäiskieli	Englanti
Pätevyys	Tohtorintutkinto
Myöntävä instituutio	Aalto-yliopisto
Valvoja/neuvonantaja	Pietola, Matti, Vastuuprofessori Pyötsiä, Jouni, Ohjaaja, Ulkoinen henkilö
Kustantaja	Aalto University
Painoksen ISBN	978-952-60-4853-6
Sähköinen ISBN	978-952-60-4854-3
Tila	Julkaistu - 2012
OKM-julkaisutyyppi	G4 Monografiaväitöskirja

Tutkimusalat

vikasimulaattori
vian havaitseminen
diagnostiikka
prosessin säätöventtiili

Pääsy asiakirjaan

http://urn.fi/URN:ISBN:978-952-60-4854-3

Siteeraa tätä

@phdthesis{f34926a46a9240d2bbdbb477205a7b5c,

title = "Fault simulator and detection for a process control valve",

abstract = "In this study a novel fault simulator for a quarter-turn pneumatic control valve is presented. Another contribution of this study is a novel fault detection and diagnosis method for a control valve. It has been possible to analytically model control valve dynamics, despite their inherent nonlinearities for the fault simulator. These nonlinearities of the system have been identified and estimated through selected parameters. The models that were derived have been verified with measurements and the modeling error is found to be acceptable for the fault simulations. Some typical control valve faults have been simulated and the impacts on the internal variables of the flow control loop and control performance analysed. The fault simulator presented here can be used for fault detection and diagnosis, as well as robust control research. On the basis of simulations and test bench test runs it is possible to detect and diagnose typical control valve faults before they have a severe impact on flow control loop performance. This can be done with the online method introduced in this study, which requires low computing power. This means that the method is implementable in an intelligent valve controller and diagnosis can be performed without disturbing the process. The method that is introduced is based on the observation that the internal variable closest to the fault compensates and reacts first to the fault when feedback control is utilised. That leads to an operation point shift for all the internal variables before the fault in the chain of the internal variables in the system. When these operation point changes are being detected, the faults can be detected and diagnosed. This principle can be utilised in all feedback-controlled mechatronic systems. The fault detection and diagnosis method introduced here was verified with the fault simulator and test bench runs and found to be applicable to the detection and diagnosis of all the faults that were tested.",

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author = "Timo Manninen",

year = "2012",

language = "English",

isbn = "978-952-60-4853-6",

series = "Aalto University publication series DOCTORAL DISSERTATIONS",

publisher = "Aalto University",

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TY - BOOK

T1 - Fault simulator and detection for a process control valve

AU - Manninen, Timo

PY - 2012

Y1 - 2012

N2 - In this study a novel fault simulator for a quarter-turn pneumatic control valve is presented. Another contribution of this study is a novel fault detection and diagnosis method for a control valve. It has been possible to analytically model control valve dynamics, despite their inherent nonlinearities for the fault simulator. These nonlinearities of the system have been identified and estimated through selected parameters. The models that were derived have been verified with measurements and the modeling error is found to be acceptable for the fault simulations. Some typical control valve faults have been simulated and the impacts on the internal variables of the flow control loop and control performance analysed. The fault simulator presented here can be used for fault detection and diagnosis, as well as robust control research. On the basis of simulations and test bench test runs it is possible to detect and diagnose typical control valve faults before they have a severe impact on flow control loop performance. This can be done with the online method introduced in this study, which requires low computing power. This means that the method is implementable in an intelligent valve controller and diagnosis can be performed without disturbing the process. The method that is introduced is based on the observation that the internal variable closest to the fault compensates and reacts first to the fault when feedback control is utilised. That leads to an operation point shift for all the internal variables before the fault in the chain of the internal variables in the system. When these operation point changes are being detected, the faults can be detected and diagnosed. This principle can be utilised in all feedback-controlled mechatronic systems. The fault detection and diagnosis method introduced here was verified with the fault simulator and test bench runs and found to be applicable to the detection and diagnosis of all the faults that were tested.

AB - In this study a novel fault simulator for a quarter-turn pneumatic control valve is presented. Another contribution of this study is a novel fault detection and diagnosis method for a control valve. It has been possible to analytically model control valve dynamics, despite their inherent nonlinearities for the fault simulator. These nonlinearities of the system have been identified and estimated through selected parameters. The models that were derived have been verified with measurements and the modeling error is found to be acceptable for the fault simulations. Some typical control valve faults have been simulated and the impacts on the internal variables of the flow control loop and control performance analysed. The fault simulator presented here can be used for fault detection and diagnosis, as well as robust control research. On the basis of simulations and test bench test runs it is possible to detect and diagnose typical control valve faults before they have a severe impact on flow control loop performance. This can be done with the online method introduced in this study, which requires low computing power. This means that the method is implementable in an intelligent valve controller and diagnosis can be performed without disturbing the process. The method that is introduced is based on the observation that the internal variable closest to the fault compensates and reacts first to the fault when feedback control is utilised. That leads to an operation point shift for all the internal variables before the fault in the chain of the internal variables in the system. When these operation point changes are being detected, the faults can be detected and diagnosed. This principle can be utilised in all feedback-controlled mechatronic systems. The fault detection and diagnosis method introduced here was verified with the fault simulator and test bench runs and found to be applicable to the detection and diagnosis of all the faults that were tested.

KW - fault simulator

KW - fault detection

KW - fault isolation

KW - fault diagnosis

KW - process control valve

KW - vikasimulaattori

KW - vian havaitseminen

KW - diagnostiikka

KW - prosessin säätöventtiili

KW - fault simulator

KW - fault detection

KW - fault isolation

KW - fault diagnosis

KW - process control valve

M3 - Doctoral Thesis

SN - 978-952-60-4853-6

T3 - Aalto University publication series DOCTORAL DISSERTATIONS

PB - Aalto University

ER -

Fault simulator and detection for a process control valve

Abstrakti

Tutkimusalat

Pääsy asiakirjaan

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