Actuator Benchmark Results

1
5-th DAMADICS Workshop

Łagów, Poland, April 5th-7th, 2004
Sergej Jegorov, Piotr Wasiewicz
ACTUATOR BENCHMARK RESULTS:

STEP I AND II
2
Presentation Plan
• Control Valve Introduction

• Step I
• Step II
• Conclusions

3
Control Valve Introduction
Actuator
Actuator structure
structure
Process
ProcessVariable
Variable
•• CV
CV –– Control
ControlValue
Value
•• ZZ –– Valve Position
Valve Position
•• P1
P1 –– Valve
Valve Input
Input Pressure
Pressure
•• P2
P2 –– Valve
Valve Output
Output Pressure
Pressure
•• FF –– Medium Flow
Medium Flow RateRate

4
Considered models of control valve
• servomotor rod movement model

Zˆ  f (CV ) (1)
• control valve model
Fˆ  f ( Z , P1 , P2 ) (2)
• actuator model
Fˆ  f (CV , P1 , P2 ) (3)
• simplified model of the control valve
Fˆ  f ( Z ) (4)
• simplified model of actuator
Fˆ  f (CV ) (5)

S5
S4
S3
S2
S1
Valve clogging
f1
±1
±1
±1
Valve plug or valve seat
-1
-1
-1
-1
f2
sedimentation
1
1
1
1
f3
Valve plug or valve seat erosion
r4 = F – F*(Z),
r5 = F – F*(CV),
r1 = Z – Z*(CV),
Increased of valve or bushing
f4
±1
±1
±1
friction -1
-1
-1
-1
f5
External leakage
Control valve vaults
1
1
1
1
f6
Internal leakage Valve clogging
(9)
(6)
r3 = F – F*(CV, P1, P2), (8)

r2 = F – F*(Z, P1, P2), (7)
(10)
Medium evaporation or critical
-1
f7
±1
±1
±1
±1
flow
Twisted servo-motor's piston rod

f8
±1
±1
±1
Servo-motor's housing or terminals

1
1
-1
f9
tightness
faults
Servo-motor's diaphragm
1
1
-1
f10
perforation
Pneumatic servo-motor
Servo-motor's spring fault

f11
Electro-pneumatic transducer
S4 = f(r4),
S3 = f(r3),
S2 = f(r2),
S1 = f(r1),
S5 = f(r5).
±1
±1
±1
f12
fault
Rod displacement sensor fault

±1
±1
±1
±1
f13
Pressure sensor fault

X
X
X
X
X
f14
Positioner faults
Positioner feedback fault

(15)
(14)
(13)
(12)
(11)
±1
±1
±1
f15
Positioner supply pressure drop

Diagnostic Matrix (theoretical)
1
1
-1
f16
Unexpected pressure change across

±1
±1
f17
the valve
Fully or partly opened bypass

1
1
1
1
f18
valves
External faults
Flow rate sensor fault

-1
-1
-1
-1
f19
5

6
FDI Structure
FD using NN, FI using Fuzzy Logic
Inputs Outputs
Process + Residuals Faults
-
Fuzzy logic
Controller
Neural Network
Fault detection Fault isolation

7
Search of Optimal NN Architecture
• Transfer functions of
all layers are logsig
1 2 3
Name Delays
Layer Layer Layer
Net 2 10 5 1
Net1 2 30 8 1
Net3 2 6 3 1
Net4 2 6 1 0

9
Data Filtering
1 1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 f_t
input_f4i z z z z z z z z z z z
z z z z z
1/12 f_2f
1/6 input_f_f4i
filter1 filter2
1 1 1 1 1 1 1 1 1 1 1
f_ t
z z z z z z z z z z z
f_ 3f
1/24
1 1 1 1 1 1 1 1 1 1 1
z z z z z z z z z z z
filter3

10
NN Architecture Search. Training data without filtering
0.8
0.8 net1 0.6
0.6 net2
0.6 0.4
0.6 0.4
0.4 0.2
0.4 0.2
0.2 0
0.2 0
0 -0.2
0 -0.2
-0.2 -0.4
-0.2 -0.4
-0.4 -0.6
-0.4 -0.6
-0.6 -0.8
0 1000 2000 3000 4000 5000 6000 0 1000 2000 3000 4000 5000 6000
-0.6 -0.8
0 1000 2000 3000 4000 5000 6000 0 1000 2000 3000 4000 5000 6000
net4
0.6
net3
0.6
0.6
0.6
0.4
0.4
0.4
0.4
0.2
0.2
0.2
0.2
0
0
0
0
-0.2
-0.2
-0.2
-0.2
-0.4
-0.4
-0.4
-0.4
-0.6
-0.6
-0.6
-0.6
-0.8
0 1000 2000 3000 4000 5000 6000
-0.8
-0.8 0 1000 2000 3000 4000 5000 6000
0 1000 2000 3000 4000 5000 6000
-0.8
0 1000 2000 3000 4000 5000 6000

11
Results achieved by applying filtering of measurements
0.6 0.6
0.6 0.6
0.4 0.4
0.4 0.4
0.2 0.2
0.2 0.2
0 0
0 0
-0.2 -0.2
-0.2 -0.2
-0.4 -0.4
-0.4 -0.4
-0.6 -0.6 Blue – NN trained on filtr1

-0.6 -0.6
Red – NN trained on filtr2
-0.8 -0.8
0
-0.8 1000 2000 3000 4000 5000 6000 0
-0.8 1000 2000 3000 4000 5000 6000
0 1000 2000 3000 4000 5000 6000 0 1000 2000 3000 4000 5000 6000
Fault f4 Fault f4
Trained on filter1 but works on filter2 Trained on filter1 and filter2, but works on filter3

Time Diagrams of real and modeled signals. NN trained 12
applying filter2, but examined using filter3

1
1 NNr2 1
1 NNr3
0.9 0.9
0.9 0.9
0.8 0.8
0.8 0.8
0.7 0.7
0.7 0.7
0.6 0.6
0.6 0.6
0.5 0.5
0.5 0.5
0.4 0.4
0.4 0.4
0.3 0.3
0.3 0.3
0.2 0.2
0.2 0.2
0.1 0.1
0.1 0.1
0 0
00 0.5 1 1.5 2 2.5 00 0.5 1 1.5 2 2.5
0 0.5 1 1.5 2 4 2.5 0 0.5 1 1.5 2 4 2.5
x 10 x 10
4 4
x 10 x 10
0.1
0.1 r2 res 0.4
0.4
r3 res
0.05
0.05 0.2
0.2
0
0
0
-0.05 0
-0.05
-0.1 -0.2
-0.1 -0.2
-0.15
-0.15 -0.4
-0.4
-0.2
-0.2
-0.6
-0.6
-0.25
-0.25
-0.8
-0.3
-0.8
-0.3
-0.35 -1
0
-0.35 0.5 1 1.5 2 2.5 0-1 0.5 1 1.5 2 2.5
0 0.5 1 1.5 2 4 2.5
0 0.5 1 1.5 2 4 2.5
x 10 x 10
4
x 10 x 10
4

Time Diagrams of real and modeled signals. NN trained applying 13
filter2, but examined using filter3

1 1
1 1
0.9 0.9
0.9 0.9
0.8 0.8
0.8 0.8
0.7 0.7
0.7 0.7
0.6 0.6
0.6 0.6
0.5 0.5
0.5 0.5
0.4 0.4
0.4 0.4
0.3 0.3
0.3 0.3
0.2 0.2
0.1
0.2
NNr4 0.1
0.2
NNr5
0.1 0.1
0 0
00 0.5 1 1.5 2 2.5 00 0.5 1 1.5 2 2.5
0 0.5 1 1.5 2 4 2.5 0 0.5 1 1.5 2 4 2.5
x 10 x 10
4 4
x 10 x 10
0.2 1
0.2 1
0.1 0.8
0.1 0.8
0.6
0
0.6
0
0.4
-0.1 0.4
-0.1
0.2
-0.2 0.2
-0.2
0
0
-0.3
-0.3
-0.2
-0.2
-0.4
-0.4 -0.4
-0.4
-0.5
-0.5 -0.6
-0.6
-0.6
r4 residual -0.6
-0.8
r5 residual
-0.8
-0.7 -1
0
-0.7 0.5 1 1.5 2 2.5 0-1 0.5 1 1.5 2 2.5
0 0.5 1 1.5 2 4 2.5
0 0.5 1 1.5 2 4 2.5
x 10 x 10
4
x 10 x 10
4

14
Measures of a Neural Networks "health"
All Weights and Biases All Weights and Biases
120 40
35
100
30
80
25
60 20
15
40
10
20
5
0 0
-11 -9 -7 -5 -3 -1 1 3 5 7 9 11 -11 -9 -7 -5 -3 -1 1 3 5 7 9 11
All Weights and Biases All Weights and Biases

40 30
35
25
30
20
25
20 15
15
10
10
5
5
0 0
-11 -9 -7 -5 -3 -1 1 3 5 7 9 11 -11 -9 -7 -5 -3 -1 1 3 5 7 9 11

S5
S4
S3
S2
S1
Valve clogging
f1
+1
+1
+1
Valve plug or valve seat
-1
-1
-1
-1
f2
sedimentation
Valve plug or valve seat erosion
f3
+1
+1
+1
+1
Increased of valve or bushing
f4
+1
+1
+1
friction
External leakage
x
x
x
x
x
f5
Control valve vaults

Internal leakage Valve clogging
f6
+1
+1
+1
+1
Medium evaporation or critical flow

f7
+1
+1
+1
Twisted servo-motor's piston rod

x
x
x
x
x
f8
Servo-motor's housing or terminals

x
x
x
x
x
f9
tightness
Servo-motor's diaphragm perforation
+1
+1
+1
motor faults
Pneumatic servo-
x
x
x
x
x
Servo-motor's spring fault

x
x
x
x
x
Electro-pneumatic transducer fault
Rod displacement sensor fault

+1
+1
+1
+1
X
X
X
X
X
Pressure sensor fault

Positioner faults
-1
-1
-1
Positioner feedback fault

+1
+1
+1
Positioner supply pressure drop

Unexpected pressure change across the
-1
-1
valve
+1
+1
+1
+1
Fully or partly opened bypass valves

External faults
0
0
0
0
0
+1
+1
+1
+1
Flow rate sensor fault .

f10 f11 f12 f13 f14 f15 f16 f17 f18 f19
free
Fault
1
0
1
0
1
f16
f1, f4,
f7, f10, f2
-1
-1
-1
-1
-1
Diagnostic Matrix (Practical)
1
1
1
1
0
f19
f18,
f13,
f3, f6,
0
0
0
0
0
f14
f12,
f5, f8,
f9, f11,
0
0
-1
-1
-1
f15
0
0
0
-1
-1
f17
DGN0 DGN1 DGN2 DGN3 DGN4 DGN5 DGN6
15

16
Fuzzification (Membership Functions)
Input Membership Functions Input Membership Functions

r1, r2, r4 r3, r5
• Sugeno Type
• Defuzzificatiom method is whatever (wtaver)

17
Examples of results of isolation of fault 1

18
Examples of results of isolation of fault 3

19
Step I results (from forms S1-FF-fx)
f1 f1m f2 f2inc f3inc f4inc f5inc f6inc f7 f7m f8 f9 f10 f11

td 5s 15s 2s 8.278e+004s 5.378e+004s 4130s - 1.672e+004s 5s 5s - - 5s -
rfd 0% 0% 0% 0% 0% 0% - 0% 0% 0% - - 0% -
rtd
0.98% 0.95% 0.99% 0.94% 0.72% 0.13% - 0.89% 0.98% 0.98% - - 0.98% -
fsd 0.75 0.5 0.75 0.98 0.64 1 - 0.19 0.75 0.5 - - 0.75 -
tit 5s 15s 2s 8.278e+004s 5.378e+004s 4130s - 1.672e+004s 5s 5s - - 5s -
rfi 0% 0% 0% 0% 0% 0% - 0% 0% 0% - - 0% -
rti 0.98% 0.95% 0.99% 0.92% 0.72% 0.02% - 0.89% 0.98% 0.98% - - 0.98% -
rmi 0% 0% 0.02% 0.38% 0.021% 0.12% - 0.01% 0.02% 0.01% - - 0.01% -
fsi 0.75 0.5 0.75 0.98 0.6403 1 - 0.19 0.75 0.5 - - 0.75 -
dacc 0.2 0.2 1 inf 0.2 0.2 - 0.2 0.2 0.2 - - 0.2 -

20
Step I results (from forms S1-FF-fx) continued
f12 f13 f13m f13inc f14 f15 f16 f17 f17 inc f18 f18m f18inc f19 f19m
td - 5s 6s 45s - 231s 7s 6s 640s 5s 6s 9409s 7s 7s
rfd - 0% 0% 0% - 0% 0% 0% 0% 0% 0% 0% 0% 0%
rtd
- 0.98% 0.97% 0.97% - 0.92% 0.97% 0.97% 0.91% 0.98% 0.97% 0.93% 0.97% 0.97%
fsd - 0.75 0.5 0.07 - 0.75 0.75 0.76 0.17 0.75 0.5 0.112 0.75 0.5
tit - 5s 6s 45s - 240s 7s 35s 640s 5s 6s 9409s 7s 7s
rfi - 0% 0% 0% - 0% 0% 0% 0% 0% 0% 0% 0% 0%
rti - 0.98% 0.97% 0.97% - 0.66% 0.97% 0.90% 0.91% 0.98% 0.97% 0.93% 0.97% 0.97%
rmi - 0.01% 0% 0% - 0.28% 0% 0.07% 0.03% 0% 0% 0% 0% 0%
fsi - 0.75 0.5 0.07 - 0.75 0.75 0.75 0.17 0.75 0.5 0.112 0.75 0.5
dacc - 0.2 0.2 0.2 - 0.07 0.2 1 1 0.2 0.2 0.2 0.2 0.2

21
Step II results
scenario 1 2 3 4 5 6 7 8 9 10 11 12
Fault or DGN5
DGN1 - DGN3 DGN5 - DGN5 DGN2 DGN5 DGN1 DGN1 DGN3
group or 1
Start time 15073 - 37619 82491 - 80965 62438 24809 20778 24129 855 55196
Stop time inf - 73370 82519 - 80979 76487 24821 49064 35621 11963 80822
scenario 13 14 15 16 17 18 19 20 21 22 23 24
Fault or
DGN6 DGN3 DGN5 DGN3 DGN3 DGN1 DGN1 - DGN2 DGN3 DGN3 DGN6
group
Start time 19817 58605 60001 30194 12430 1940 22556 - 18238 7400 5773 10717
Stop time 23743 77130 60014 Inf Inf 10039 35085 - Inf inf inf Inf

22
Conclusions
• fault detection subsystem based on neural network technology was
developed
• fault isolation subsystem based on fuzzy logic technology was
developed
• Neuro-fuzzy FDI system is applicable for actuator fault diagnosis.
Fault groups are distinguishable.
• Close to 1, true fault detection rates factors achieved in Step I
confirms acceptable NN models quality
• High values of true fault isolation rates (Step I) confirms proper
isolability features of fuzzy isolation scheme applied
• Results achieved in Actuator Benchmark Step I are highly
acceptable
• The fault distinguishability problem exists because of limited
availability of measurements when considering industrial
benchmark Step II). In this case 6 fault groups are distinguishable.


Actuator Benchmark Results

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Actuator Benchmark Results

Uploaded by

Copyright:

Available Formats

1

5-th DAMADICS Workshop

Sergej Jegorov, Piotr Wasiewicz