R. I. TU Darmstadt

IFAC SAFEPROCESS: - History, Status, Experiences -

Rolf Isermann

Darmstadt University of TechnologyInstitute of Automatic Control

Darmstadt, Germany

Opening Session 7th IFAC Symposium SAFEPROCESS, Barcelona, 1st July 2009

R. I. TU Darmstadt

IFAC SAFEPROCESS

1. History

2. Status

3. Experiences

4. Outlook

R. I. TU Darmstadt

O On the history of IFAC SAFEPROCESS

– Until 1990: fault detection and supervision treated in special sessions of symposia and congresses

– 1989: Application for a Conference SAFEPROCESS by German NMO accepted

– 1st Symposium SAFEPROCESS in Baden-Baden, 10-13 Sep. 1991– Title SAFEPROCESS was selected as abbreviation of the field (similar as

IFAC/IFIP Workshops SAFECOMP for computer systems)– 1991: Steering committee founded in Baden-Baden to support continuity– 1993: IFAC Technical Committee SAFEPROCESS accepted within the

Application Committee of the IFAC Technical Board– 1993: Technical Board accepts IFAC SAFEPROCESS on the Masterplan

for Symposia– 1994: 2nd IFAC Symposium SAFEPROCESS in Espoo, Finland:

→ A new Symposium series got started

R. I. TU Darmstadt

Preface Proceeedings1 st IFAC-SAFEPROCESS1991

R. I. TU Darmstadt

Preface of Preprints 1st IFAC SAFEPROCESS 1991 Baden-Baden

RI 1991

R. I. TU Darmstadt

Rolf IsermannBernd Freyermuth

• 137 papers• 287 participants• 55 % from industry

R. I. TU Darmstadt

Pentti LautalaBjörn WahlströmTuula Ruokonen

• 133 papers• 220 participants

R. I. TU Darmstadt

Ron J. PattonSteve DaleyJie Chen

• 209 papers• 200 participants

R. I. TU Darmstadt

Josef BokorAndras M. EdelmayerCsilla Banyasz

• 200 papers• 200 participants

R. I. TU Darmstadt

Janos GertlerMarcel StaroswieckiN. Eva Wu

• 197 papers• 175 participants

R. I.TU Darmstadt

 

                                                   

 

                                                  

 

                                                   

 

                                                  

                                                                                                       

Beijing, P.R. China

August 29-September 1 ,2006

6th IFAC Symposium on  

Fault Detection, Supervision and Safety of Technical Processes

J. KorbiczD.H. ZhouH.Y. Zhang

258 papers201 partipants

R. I. TU Darmstadt

Janos GertlerRon Patton

Joseba QuevedoTeresa EscobetVicenc PuigBernardo MorcegoAndreu Quesada

264 papers292 participants (207 professionals 85 students) (26 June 09)

R. I. TU Darmstadt

IFAC

O IFAC Technical Committee Chemical Process Control:– IFAC Workshops: Fault detection and supervision in the chemical process

industries• 1992: Newark-Delaware, USA• 1995: Newcastle, UK• 1998: Solaize-Lyon, FR• 2001: Cheju, KR

O IFAC Congresses:• 1990 Tallinn: 1 session• 1993: Sydney: 4 sessions• 1996: San Francisco: 9 sessions• 1999: Beijing: • 2002: Barcelona: 13 sessions• 2005: Prague: 11 sessions, • 2008: Seoul: 5 sessions + CC1, CC2

R. I. TU Darmstadt

IFAC SAFEPROCESS

1. History

2. Status

3. Experiences

4. Outlook

R. I. TU Darmstadt

O IFAC Technical Committee SAFEPROCESS :

– Planning and organisation of new Symposia• Foundation of International Program Committees• Selection of Guest-Countries• Design and maintenance of TC web page• TC Chairs act for 3 years, can be expanded to another 3 years• 2008: 65 members

– Organisation of Sessions for IFAC Congresses– 1991- 1996: Terminology on fault detection and diagnosis

• Control Engineering Practice 5 (1997), 709-719• http://www.rtm.tu-darmstadt.de/fd_terminology.html

– Technical Committee Chairs:• 1991 – 1996 Rolf Isermann• 1996 - 2002 Ron Patton• 2002 – 2008 Michel Kinnaert / Michelle. Basseville/ Jakob Stoustrup• 2008 - 2011 Jakob Stoustrup / Michel Kinnaert /Michel Verhaegen

R. I. TU Darmstadt

IFAC SAFEPROCESS

1. History

2. Status

3. Experiences• Methods• Applications

4. Outlook

R. I. TU Darmstadt

Fault Management

Fault-management actions

Ope-rator

F Fault

Alarm

ChangeOperation

Reconfi-guration

Decision

Hazard Classes

FaultEvaluation

Fault

FaultDiagnosis

Symptoms

FaultDetection

Protection

SignalEvaluation

StopOperation

[W, U] C P[U, X, Y]

FeatureGeneration

Features

Mainte-nance

Repair

Process and Control

Measurements

Con

trol

and

Pro

cess

Lev

el

Supervisionw. FaultDiagnosis

Protec-tion

Monitoring

Sup

ervi

sory

Lev

el

R. I. TU Darmstadt

limitchecking

signalmodels

used

FAULT- DETECTION METHODS

detection withsingle signals

detection with multiplesignals and models

processmodels

used

multi-variatedata

analysis

trendchecking

spectrumanalysis

fixedthres-hold

change-detectionmethods

correla-tion

Waveletanalysis

adaptivethresh-olds

neuralnetworks

param.estim.

stateob-

servers

stateestim.

parityequa-tions

principalcomponent

analysis

Extract of fault detection methods

R. I. TU Darmstadt

IFAC SAFEPROCESS

1. History

2. Status

3. Experiences• Methods• Applications

R. I. TU Darmstadt

Research projects at IAT (33 Doctoral thesis 1981 – 2008, 50 % industry projects):

1. Electrical drivesO DC motors

• With brushes• Electronic commutation

O Inductionmotors• Asynchroneous motors frequency

controlled, with inverters

O Universalmotors

2. ActuatorsO Electrical throttleO Electrical cabine pressure valve

(aircraft ,BLDC)O Pneumatic cylinder- and

membrane actuatorsO Hydraulic Servoaxis

3. PumpsO Centrifugal pumps with DC- and AC-

motorsO Reciprocating pump

(oscillating pump)

4. Plants• Pipeline leak detection and localization

liquids and gases (ethylen)• Heat exchangers (steam/water., heating boilers)

5. Manufacturing• Feeddrive (DC-, Synchron-Mot)• Production center (MAHO MC5)

main drive, feed drives milling, drilling, turning

• Grinding machines• Industrial robot (6 axes)

6. Automobiles

• Suspension, active suspension (ABC)• Hydraulic brake system• Drive dynamic stability, over-, understeering• Fault-tolerant sensor platform

7. Internal combustion engines• Gasoline engines• Diesel engines

8. Fault-tolerant systems• Duplex-Asynchroneous-drivee • Duplex-valve hydraulic servo system

→ Isermann, R.: Fault Diagnosis of Technical Processes, Springer-Verlag, Berlin, 2009/2010

Theoretical and experimental experiences in development of fault diagnososi methods

R. I. TU Darmstadt

Require-ments

Process-analysis.

- process: - linearizable - nonlinear- operation - stationary - dynamic- signals: - periodic - stochastic

- available measurements- operating conditions- open/closed loop

Selectionfault detectionmethods

- signal model based: - Fourieranalys. - wavelets, …- process model based: - paramet. estim. - parity equations - observers, K.F. .

- adjustment to real process and real signals- modeltypes: - linear - nonlinear - time variant- test signals: - yes: type - no

Simulations

- process modeling: - physical - identification - semi-physical- signal models: - periodic, harmonics - ARMA - disturbances

- test of methods- combination of methods- fault coverage- fault

diagnosis: - isolability - classification - inference meth.

feedbacks for improvements

- kind of faults- number of faults- fault detection coverage- smallest replaceable unit

- fault list: - actuators - process - sensors- fault-sympt. trees- application? - maintenance - fault tolerance

Preco

nd

ition

sR

esults

Development stages for fault detection and diagnosis

- process computer - real time - filtering,….- real operating conditions - real signals- inserting real faults

- adjustment of: - models - filters - tuning parameters- faults: - detecable ? - size ? - diagnosible ?

Experimentswithreal process

- field tests- all operating conditions- reliability ?- maintainability ?- customer acceptance ?

FinalSoftw/hardw.realization.

- tests with other processes- robustness issues (process tolerances)

compari-son

Ready

for use

R. I. TU Darmstadt

Outlook: Technical driving forces for SAFEPROCESS ?1. Asset management → improvement of availability and economics

• Maintenance on demand• Forecast of maintenance• Estimation of availability• Life cycle optimization

2. Fault tolerant systems → improvement of safety (and availability)• Fault tolerant sensors• Fault tolerant actuators and drives• Fault tolerant processes• Fault tolerant control• Until now: for safety relevant systems only

3. Development tools → improvement of applicability• for fault detection and diagnosis methods• user friendly, with best practice approaches• Integration of analytical + heuristic information on process behavior• Combined diagnosis for continuous + discrete event processes

R. I. TU Darmstadt

O Important issues for successful detection & diagnosis methods:

1. Physical/technical understanding of fault propagation to measured signals

2. Physical & experimental based modeling of actuators, processes and sensors

3. Adjustment of suitable detection methods to real faults

4. Experimental and engineering skill & validation of methods

R. I. TU Darmstadt

Fault diagnosis + fault management: wide technical applications