BENEFIT OF FAULT DETECTION SYSTEM

ABSTRACT

This paper study on the bene it o au!t dete"tion syste# in "he#i"a! pro"ess$ E%ery "he#i"a! pro"esses ha%e probabi!ity to ai!ure$ This situation en or"es the resear"hers and industria! to ind the appropriate te"hni&ues to dete"ted a pro"ess ai!ure as ear!y as possib!e$ The best so!ution is by i#p!e#entin' au!t dete"tion syste# (FDS) be"ause this au!t dete"tion ha%e a !ot o ad%anta'es and bene it either or the pro"ess or or the industria!$ In these studies a!so sho* the i#portant o au!t dete"tion syste# in "he#i"a! pro"ess and a!so state so#e e+a#p!es o au!t dete"tion syste# studies by estab!ish resear"hers$

INTRODUCTION

A""ordin' to state#ent by Fran, and -oppen Se!i'er.(/001a b). they "!ai# that au!t is an additiona! input that "ans disturb the syste#2s per or#an"e$ For Iser#ann 3 Ba!!e. (/004). a au!t "an be de ined as any non5per#itted de%iation ro# an a""eptab!e beha%iour by at !east one o the "hara"teri6ation$ Nor#a!!y. a au!t "an be "!assi ied by te#porary or per#anent physi"a! "han'es in the syste# (Le'er et al., /007)$ The physi"a! "han'es are either in"ipient (so t) or abrupt (hard) (Bo"ania!a and Sa da Costa. 8994)$

The #ost "o##ent types o au!t dete"tion are sensor fault , actuator fault and process plant fault (Fran,. /009. :u'!ie!#i et al., /00;)$ In parti"u!ar the syste# "an be used or au!t dia'nosis to 'enerate *arnin' and a!ar# si'na!. au!t iso!ation to !o"ate the au!t. au!t e%a!uation to deter#ine the au!t si6e and !ast!y au!t re"o%ery to ensure syste# operation. e%en throu'h de'raded$ Further. the abo%e #ethods are a!so spe"ia!i6ed a""ordin' to the type o au!t. *hi"h in 'enera! "an be di%ided into t*o broad "ate'ories *hi"h are abrupt au!ts and in"ipient au!t$ Abrupt au!ts are dra#ati" and persistent due to si'ni i"ant de%iations ro# steady state operation. ho*e%er in"ipient au!ts o""ur re!ati%e!y s!o*!y o%er ti#e and they are !in,ed to *ear and tear o "o#ponents and dri t in "ontro! para#eters$ It shou!d be stressed that the e%a!uation and "o#parison o the a oresaid di erent #ethods are based on the o!!o*in' properties (:ert!er. /077)$ First it is probabi!ities o "orre"t dete"tion. a!se a!ar#. non5a!ar# or in"orre"t iso!ation se"ond!y is sensiti%ity and !ast robustness$

Fau!t dete"tion is a binary de"ision #a,in' pro"ess sta'e. either the syste# is un"tionin' proper!y or there is a au!t o""urren"e$ This step deter#ine the presents o au!t in a syste# and the ti#e o dete"tion$ Fau!t iso!ation is a urther pro"ess to deter#ine the au!t sour"e and it per or#ed on!y a ter the de!i%eran"e o a au!t dete"tion a!ar#$ On"e a "han'e is dete"ted ro# the #ode! para#eter. it #ay ne"essary to iso!ate *hi"h or *hi"h set para#eters ha%e han'ed$ Then au!t dia'nosis sta'e is #ore di i"u!t be"ause it a!so shou!d ind and dia'nose the root "ause o the prob!e#$ In this sta'e it a!so deter#ines the ,ind. si6e. !o"ation and ti#e o au!ts presents$

AD<ANTA:ES OF FAULT DETECTION SYSTEM

Any pro"ess syste# is !iab!e to au!t$ A!thou'h a 'ood desi'n is i#p!e#ented to #ini#i6e the au!ts ro# o""urrin'. the situation "annot be u!!y re#o%ed$ The on!y *ay to o%er"o#e the 'ro*in' au!ts pheno#ena is by usin' the dete"tion syste#$ Nu#erous app!i"ations o au!ts dete"tion syste# are reported in the !iterature #ain!y in the area o aeronauti"a! and aerospa"e syste#. auto#oti%e and tra i" syste#s. "he#i"a! pro"esses. e!e"tri"a! and e!e"troni" syste#. nu"!ear p!ants. po*er syste# and transportation syste#s (Iser#ann and Ba!!e. /004)$

Current!y. the au!t dete"tion syste# is %ery i#portant in the "he#i"a! industry be"ause o the de#and on indin' the appropriate #ethod that "o%ers the sa ety. re!iabi!ity and a%ai!abi!ity$ The purpose o the dete"tion syste# is 'enera!!y to 'enerate an a!ar# to in or# the operators that there is at !east one au!t has o""urred in the syste# (=an' and Da!ey. /004)$ The dete"tion o au!t shou!d be as ear!y as possib!e be ore it s!o*!y propa'ates e!se*here (>a#sa5 >oune!a et al., 899?@ A%oy. 8998@ Fran, and -oppen5Se!i'er. /001a. b@ Iser#ann. /001@ Aatton et al., /00B)$ The dete"tion at an ear!y sta'e *i!! he!p the operators to "ountera"tion the prob!e# by re"on i'urin'. #aintainin' and repairin' the au!ty syste# (Iser#ann. /001)$ The on!y *ay to 'et an ear!ier dete"tion is by obtainin' as #u"h in or#ation as possib!e re!ated to the pro"ess or syste#$

In #ost o the "he#i"a! industries. these are t*o #ain prob!e#s that are a!*ays interruptin' the operators to 'et an a""urate readin' and #ore in or#ation *hi"h it is "aused by e&uip#ent #a! un"tions or pro"ess disturban"e$ O these t*o. pro"ess disturban"es are usua!!y #ore di i"u!t to dete"t (=an' and Da!ey. /004)$ Dete"tion o the pro"ess disturban"e is i#portant sin"e it redu"es the o""urren"e o produ"tion that does not #eet the &ua!ity "riteria$ The redu"tion o the produ"t &ua!ity *i!! "ontribute to the e"ono#i" i#pa"t$

The resear"h *or, on the au!t dete"tion syste# is sti!! on'oin'$ The ben"h#ar, studies are "urrent!y set5up in the three a"tuators in e%aporation se"tion at the Lub!in su'ar a"tory in Ao!and (B!an,e et al., /00;)$ This ben"h#ar, *hi"h is nor#a!!y ,no*n as DAMADIC (De%e!op#ent and App!i"ation o Methods or A"tuators Dia'nosis in Industria! Contro! Syste#) *as purpose!y desi'ned to study a *ide ran'e o au!t dete"tion and iso!ation #ethods (Bartys et al., 8994)$ The introdu"tion o this DAMADICS "an be urther re erred to the *or, o B!an,e et al., (/00;). B!an,e and Aatton (/00;) and Co !in' et al., (/00;)$ So#e o the resu!ts "an be seen ro# Bartys et al., (8994)@ Bo"anai!a and Sa da Costa. (8994b)@ Ca!ado et al., (8994)@ Duste'or et al., (8994)@ -os"ie!ny et al.,(8994)@ Aui' et al.,(8994) and =it"6a, et al., (8994)$

TCE IMAORTANT OF FAULT DETECTION SYSTEM

The "o#p!e+ity o the #ost "he#i"a! industry a!*ays tends to "reate a prob!e# in #onitorin' and super%ision syste#$ The prob!e# or upset e+perien"ed in one area o the p!ant *i!! 'i%e an i#pa"t to the operations o other se"tion (Shin and <en,atasubra#anian. /004)$ The au!t dete"tion in a"tua! has a potentia! to de#and on sa ety. re!iabi!ity. e i"ien"y. &ua!ity and pro itabi!ity 'i%e another "ha!!en'e to the industry and resear"hers to ind te"hni&ue in redu"in' and pre%ent any dan'erous state ro# propa'ate$ The "e!! o -oppen5Se!i''er. /001a. b)$ au!t to!eran"e in auto#ati" "ontro! syste# that !oo,s has a bi' potentia! to so!%e this prob!e# (Fran, and

A""ordin' to Fran, and -oppen5Se!i''er (/001a. b) the au!t to!eran"e "an be a"hie%ed either by passi%e or a"ti%e strate'ies$ The passi%e approa"h #a,es use o robust "ontro! te"hni&ues to ensure that the "!osed5!oop syste# be"o#e insensiti%e *ith respe"t to the au!ts$ In other hand. the a"ti%e approa"h au!t a""o##odation su"h as the "on i'uration o the "ontro! syste# *hen a au!t has o""urred$ The au!t to!eran"e is not Dust to dete"t any in"ipient au!ts sensors and a"tuator but preser%in' a per or#an"e in a 'ood &ua!ity and sa ety #anner (Boni%ento et al., 899B)$

Fau!t dete"tion. iso!ation and dia'nosis are %ery i#portant in the "he#i"a! pro"ess industry$ It is a step o the #aintenan"e pro"ess (Aubrun et al., /00;)$ By app!yin' the s"hedu!ed #aintenan"e. it *i!! he!p the pro"ess runnin' in the 'ood "ondition and the sa ety #anner$ The study o au!t dete"tion is %ery i#portant not Dust to the #aintenan"e o the e&uip#ent and pro"ess but it in"!udes the #aintained yie!d and &ua!ity o the pro"ess (Dash and <en,atasubra#ania#. 8999)$ The appropriate syste# and #ethod o au!t dete"tion "an a%oid produ"t deterioration. per or#an"e de'radation. #aDor da#a'e to the e&uip#ent and hu#an hea!th e%en "ause "asua!ty (:ar"ia et al., 8999)$ For ob%ious reasons o sa ety and e"ono#i"s. au!t dete"tion ha%e be"o#e an inte'ra! part o pro"ess desi'n (Ra!ston et al., 899/)$

The Abnor#a! Situation Mana'e#ent (ASM) dea!s *ith ti#e!y dete"tion and dia'nosis. assess#ent o the abnor#a! situation and "ounter#easure p!annin' and the irst step o the ASM is the Fau!t Dete"tion and Dia'nosis (FDD)$ A""ordin' to Dash and "o5*or,er (8999) and Ni##o (/00;). abnor#a! situation #ana'e#ent *i!! he!p to a%oid e%ent pro'ression and hen"e redu"e the a#ount o produ"ti%ity !oss durin' abnor#a! e%ent$

Situation Inade&uate #ana'in' o abnor#a! situation "aused annua! !osses o E89 bi!!ion or

petro"he#i"a! industry in the USA (Ni##o. /00;)$ This "ost *as "aused by pre#ature shutdo*n. subopti#a! operation o the pro"ess and %io!ation o sa ety and en%iron#enta! re'u!ations$ Si#i!ar a""idents a!so "ost a !ot o British e"ono#y. around E81 bi!!ion do!!ars e%ery year (Laser. 8999)$ These "onsiderations pro%ide a stron' #oti%ation re"o%ery and pre%ent au!t the propa'atin' into the tota! au!ts$ or the de%e!op#ent o #ethods or desi'n o ad%anta'es au!t dete"tion syste# to enhan"e the au!t

The desi'n o the au!t #onitorin' syste# is a "ha!!en'in' resear"h area espe"ia!!y *hen "onsiderin' the pra"ti"a! si'ni i"ant (Chan' et al., /00?)$ A%oy et al.,(899B) and A%oy (8998) #entioned that the !atest inte!!i'ent "ontro! shou!d not Dust o"us on #ode!!in' and opti#i6ation. but a!so "o%erin' the area o au!t dete"tion and iso!ation$ Traditiona! approa"h o au!t dete"tion in%o!%es "he",in' o so#e %ariab!es or the app!i"ation o redundant sensors (Fran,. /009@ :ar"ia et al., 8999@ Iser#ann. /07B)$ This #ethod is based on #athe#ati"a! #ode!s and has !in,ed bet*een input and output %ariab!es$ No*adays. the study on the au!t dete"tion "an be "onsidered as a!ready at a #ature sta'e e%en throu'h the suitab!e and appropriate #ethod is sti!! under de%e!op#ent$ The reports e#phasi6ed on the au!t dete"tion are reported by Do"hain et a!$. (8994)$

REFUIREMENT OF FAULT DETECTION SYSTEM

In order to #a,e a 'ood au!t dete"tion syste# there are se%era! "riteria that #ust be o!!o*ed by a!! dete"tion syste#s$ These "riteria *i!! #a,e the syste# iso!abi!ity tests *here the thresho!ds are p!a"e "!ose to 6ero$ In the presen"e o noise these thresho!ds #ay ha%e to be "hosen "onser%ati%e!y$ Thus. robustness needs to be ba!an"ed *ith those per or#an"es$ No%e!ty Identi i"ation Identi yin' Mu!tip!e Fau!ts E+p!anation Fa"i!ity C!assi i"ation Error Esti#ation Adaptabi!ity Reasonab!e Stora'e and Co#putationa! Re&uire#ent

Other than the abo%e re&uire#ents. Ao*er and Bahri (899B) states other "ondition that shou!d "onsist in e%ery au!t dete"tion syste#$ These "onditions in"!udeG Abi!ity to satis y rea!5ti#e re&uire#ents Easy to i#p!e#ent and understand Easy to e+tend and in"orporate ne* au!ts Aro%idin' adaptabi!ity Abi!ity to a""o##odate noisy data Abi!ity to in"orporate di erent types o input data

AAALICATION OF FAULT DETECTION SYSTEM IN CCEMICAL AROCESS

In re"ent years in industry. "he#i"a! rea"tor has been *ide!y used in the de%e!op#ent o au!t dete"tion syste#$ Che#i"a! rea"tor su"h as bat"h and CSTR are a#on' the #ost "o##on!y uti!i6ed$

Rui6 et al., (8999) de%e!oped a au!t dete"tion syste# usin' ANN (Arti i"ia! Neura! Net*or,) stru"ture supp!e#ented *ith ,no*!ed'e based e+pert syste# (-EBES)$ In this resear"h. the "ase study "orresponds to a bat"h rea"tor as introdu"ed by Luyben (/009)$ The rea"tion *as an e+other#i" rea"tion and the te#perature *as "ontro!!ed by "oo!in' *ater$ Se%en possib!e au!ts are "onsidered su"h that !ea,in' o stea# "ontro! %a!%e. !ea,in' o *ater "ontro! %a!%e. ou!in' o rea"tor te#perature probe. ou!in' o rea"tor Da",et. ou!in' o rea"tor *a!! and in"orre"t o #aster and s!a%e 'ain$ A""ordin' to Rui6 et al., (899/) they presented another t*o "ase studies usin' ed5bat"h rea"tor and #u!tipurpose bat"h p!ant$

Hhou et al., (899?) has de%e!oped the po!y#ethy#etha"ry!ate (AMMA) ro#

au!t dete"tion syste# #ethy!#etha"ry!ate

or produ"tion o (MMA) and

a6obisisobutyronitri!e (AIBN)$ The au!t dete"tion studies uti!i6ed eed or*ard neura! net*or, and radia! basis un"tion "!assi ier to iso!ate the au!ts$ The studies *ere per or#ed as si#u!ation o bat"h po!y#eri6ation rea"tor$ Te#perature sensor au!t ou!in' o rea"tor Da",et *ere assu#ed as the au!ts$ Both au!ts *ere si#u!ated by #easured te#perature and Da",et heat trans er "oe i"ient$

Lee et al., (899?) proposed "onse"uti%e updated MACA #ode! o the au!t dete"tion syste#$ In this study. the e+peri#enta! *as "arried out in ed5bat"h peni"i!!in er#entation$ The #onitorin' and "ontro! o bio#ass and peni"i!!in "on"entration *ere done on5!ine by usin' AenSi# %8$9 si#u!ator$ The si#u!ator syste# *ere "apab!e to si#u!ate the "on"entration o bio#ass. CO8. hydro'en ion. peni"i!!in. "arbon sour"e. o+y'en as *e!! as heat 'enerated durin' 'eneration o peni"i!!in$ The "han'e o initia! "u!ture %o!u#e is ro# /99 to /98 !iter and "han'e o te#perature set point o biorea"tor a"ted as the au!ts o the pro"ess$

Chetouani (899B) app!ied E+tended -a!#an Fi!ter (E-F) or the de%e!op#ent o

au!t

dete"tion syste# in "he#i"a! synthesis o a !aboratory si6e rea"tor the o+idation o sodiu# thiosu! ate by hydro'en pero+ide *as "hosen as the pro"ess rea"tion$ A "han'e in the "oo!in' te#perature and a "han'e in the rea"tant !o* rate *ere set as the au!ts or the pro"ess$

Den' and Tian (8994) proposed a #onitorin' syste# or a CSTR syste# based on #u!ti5s"a!e ,erne! prin"ip!e "o#ponent ana!ysis (MS-ACA)$ The proposed pro"ess #onitorin' and au!t dia'nosis *as tested on an e+other#i" non5isother#a! "ontinuous stirred tan, rea"tor (CSTR) syste#$ In this study. ten pro"ess au!ts *ere "onsidered *here a!! data *ere 'enerated by si#u!ation pro"ess$ Ten pro"ess au!ts "onsidered in this study in"!ude the step "han'e in eed !o* rate. the "han'e o eed te#perature. the "han'e o eed "on"entration. the "han'e o heat trans er "oe i"ient. "ata!yst dea"ti%ation. the "han'e o "oo!ant eed

te#perature. the "han'e o set point o rea"tor te#perature. the bias in rea"tor te#perature #easure#ent. the bias in "oo!ant te#perature #easure#ent and the i+ed o "oo!ant %a!%e at steady state %a!%e$ The robustness o au!t dete"tion syste# in etho+o!ate rea"tor is studied by Aetersen and

M"Far!ane (899B)$ Li&uid ethy!ene o+ide *as bubb!ed under pressure throu'h a!"oho! durin' a series o sta'es in *hi"h etho+o!ate *as initia!!y or# the a!!o*ed to 'ro* in "hain !en'th$ The study used no5!inear <issi#I si#u!ation or the data "o!!e"tion and on5!ine #onitorin' syste#$ Four pro"ess %ariab!es *ere #easured on5!ine durin' the pro"ess su"h as rea"tor te#perature. Da",et "oo!in' *ater te#perature. ethy!ene o+ide !o* rate and rea"tor pressure$ For the purpose o au!t dete"tion syste#. our pro"ess au!ts *ere "onsidered. *hi"h in"!udes the "oo!in' syste# ai!ure. e+"essi%e pro'ress o e+other#ni" rea"tion. %is"osity %ariation in rea"tor "ontent and a!so ou!in' o re"tor *a!!$

CONCLUSION

For the "on"!usion. the resu!ts ro# this study sho* au!t dete"tion syste# is used as the *arnin' a!ar# that 'i%e ear!y *arnin' to the operator about the ai!ure o the pro"ess$ So that by usin' these au!t dete"tion syste# it 'i%e #ore ad%anta'e and bene it to the "he#i"a! pro"ess itse! beside pro%ide sa ety *or,in' en%iron#ent and a!so o er pro it to the "o#pany$ The au!t dete"tion in a"tua! has a potentia! to de#and on sa ety. re!iabi!ity. e i"ien"y. &ua!ity and pro itabi!ity 'i%e another "ha!!en'e to the industry and resear"hers to ind te"hni&ue in redu"in' and pre%ent any dan'erous state ro# propa'ate$ The se%era! resear"hers ha%e e+p!ored the de%e!op#ent o the 'eneration o #ode!!in' data$ au!t dete"tion syste# on %arious "he#i"a! pro"ess rea"tors based on si#u!ated pro"ess. rather than per or#in' the rea! e+peri#ent or