The use of fault detection and diagnostics to reduce air handling unit energy consumption

The contribution of buildings towards total worldwide energy consumption in developed countries is between 20% and 40%. Heating Ventilation and Air Conditioning (HVAC), and more specifically Air Handling Units (AHUs) energy consumption accounts on average for 40% of a typical medical device manufacturing or pharmaceutical facility’s energy consumption. Studies have indicated that 20 – 30% energy savings are achievable by recommissioning HVAC systems, and more specifically AHU operations, to rectify faulty operation. Automated Fault Detection and Diagnosis (AFDD) is a process concerned with potentially partially or fully automating the commissioning process through the detection of faults. An expert system is a knowledge-based system, which employs Artificial Intelligence (AI) methods to replicate the knowledge of a human subject matter expert, in a particular field, such as engineering, medicine, finance and marketing, to name a few. This thesis details the research and development work undertaken in the development and testing of a new AFDD expert system for AHUs which can be installed in minimal set up time on a large cross section of AHU types in a building management system vendor neutral manner. Both simulated and extensive field testing was undertaken against a widely available and industry known expert set of rules known as the Air Handling Unit Performance Assessment Rules (APAR) (and a later more developed version known as APAR_extended) in order to prove its effectiveness. Specifically, in tests against a dataset of 52 simulated faults, this new AFDD expert system identified all 52 derived issues whereas the APAR ruleset identified just 10. In tests using actual field data from 5 operating AHUs in 4 manufacturing facilities, the newly developed AFDD expert system for AHUs was shown to identify four individual fault case categories that the APAR method did not, as well as showing improvements made in the area of fault diagnosis.

Industrial fault detection and diagnosis using Bayesian belief network

Rapid development in industry have contributed to more complex systems that are prone to failure. In applications where the presence of faults may lead to premature failure, fault detection and diagnostics tools are often implemented. The goal of this research is to improve the diagnostic ability of existing FDD methods. Kernel Principal Component Analysis has good fault detection capability, however it can only detect the fault and identify few variables that have contribution on occurrence of fault and thus not precise in diagnosing. Hence, KPCA was used to detect abnormal events and the most contributed variables were taken out for more analysis in diagnosis phase. The diagnosis phase was done in both qualitative and quantitative manner. In qualitative mode, a networked-base causality analysis method was developed to show the causal effect between the most contributing variables in occurrence of the fault. In order to have more quantitative diagnosis, a Bayesian network was constructed to analyze the problem in probabilistic perspective.

Recursive actuator fault detection and diagnosis for emergency landing of UASs

This paper presents a practical recursive fault detection and diagnosis (FDD) scheme for online identification of actuator faults for unmanned aerial systems (UASs) based on the unscented Kalman filtering (UKF) method. The proposed FDD algorithm aims to monitor health status of actuators and provide indication of actuator faults with reliability, offering necessary information for the design of fault-tolerant flight control systems to compensate for side-effects and improve fail-safe capability when actuator faults occur. The fault detection is conducted by designing separate UKFs to detect aileron and elevator faults using a nonlinear six degree-of-freedom (DOF) UAS model. The fault diagnosis is achieved by isolating true faults by using the Bayesian Classifier (BC) method together with a decision criterion to avoid false alarms. High-fidelity simulations with and without measurement noise are conducted with practical constraints considered for typical actuator fault scenarios, and the proposed FDD exhibits consistent effectiveness in identifying occurrence of actuator faults, verifying its suitability for integration into the design of fault-tolerant flight control systems for emergency landing of UASs.

A sensor fault detection and isolation method in interior permanent-magnet synchronous motor drives based on an extended Kalman filter

Interior permanent-magnet synchronous motors (IPMSMs) become attractive candidates in modern hybrid electric vehicles and industrial applications. Usually, to obtain good control performance, the electric drives of this kind of motor require one position, one dc link, and at least two current sensors. Failure of any of these sensors might lead to degraded system performance or even instability. As such, sensor fault resilient control becomes a very important issue in modern drive systems. This paper proposes a novel sensor fault detection and isolation algorithm based on an extended Kalman filter. It is robust to system random noise and efficient in real-time implementation. Moreover, the proposed algorithm is compact and can detect and isolate all the sensor faults for IPMSM drives. Thorough theoretical analysis is provided, and the effectiveness of the proposed approach is proven by extensive experimental results.

Actuator fault detection and isolation in linear systems

A scheme for the detection and isolation of actuator faults in linear systems is proposed. A bank of unknown input observers is constructed to generate residual signals which will deviate in characteristic ways in the presence of actuator faults. Residual signals are unaffected by the unknown inputs acting on the system and this decreases the false alarm and miss probabilities. The results are illustrated through a simulation study of actuator fault detection and isolation in a pilot plant doubleeffect evaporator.

Improving fault detection and reliability in FDDI networks

FDDI (Fibre Distributed Data Interface) is a 100 Mbit/s token ring network with two counter rotating optical rings. In this paper various possible faults (like lost token, link failures, etc.) are considered, and fault detection and the ring recovery process in case of a failure and the reliability mechanisms provided are studied. We suggest a new method to improve the fault detection and ring recovery process. The performance improvement in terms of station queue length and the average delay is compared with the performance of the existing fault detection and ring recovery process through simulation. We also suggest a modification for the physical configuration of the FDDI networks within the guidelines set by the standard to make the network more reliable. It is shown that, unlike the existing FDDI network, full connectivity is maintained among the stations even when multiple single link failures occur. A distributed algorithm is proposed for link reconfiguration of the modified FDDI network when many successive as well as simultaneous link failures occur. The performance of the modified FDDI network under link failures is studied through simulation and compared with that of the existing FDDI network.

Nonlinear PCA with Local Approach for Diesel Engine Fault Detection and Diagnosis

This brief examines the application of nonlinear statistical process control to the detection and diagnosis of faults in automotive engines. In this statistical framework, the computed score variables may have a complicated nonparametric distri- bution function, which hampers statistical inference, notably for fault detection and diagnosis. This brief shows that introducing the statistical local approach into nonlinear statistical process control produces statistics that follow a normal distribution, thereby enabling a simple statistical inference for fault detection. Further, for fault diagnosis, this brief introduces a compensation scheme that approximates the fault condition signature. Experimental results from a Volkswagen 1.9-L turbo-charged diesel engine are included.

An Interval Intelligent-based Approach for Fault Detection and Modelling

Not considered in the analytical model of the plant, uncertainties always dramatically decrease the performance of the fault detection task in the practice. To cope better with this prevalent problem, in this paper we develop a methodology using Modal Interval Analysis which takes into account those uncertainties in the plant model. A fault detection method is developed based on this model which is quite robust to uncertainty and results in no false alarm. As soon as a fault is detected, an ANFIS model is trained in online to capture the major behavior of the occurred fault which can be used for fault accommodation. The simulation results understandably demonstrate the capability of the proposed method for accomplishing both tasks appropriately

Time misalignments in fault detection and diagnosis

El desalineamiento temporal es la incorrespondencia de dos señales debido a una distorsión en el eje temporal. La Detección y Diagnóstico de Fallas (Fault Detection and Diagnosis-FDD) permite la detección, el diagnóstico y la corrección de fallos en un proceso. La metodología usada en FDD está dividida en dos categorías: técnicas basadas en modelos y no basadas en modelos. Esta tesis doctoral trata sobre el estudio del efecto del desalineamiento temporal en FDD. Nuestra atención se enfoca en el análisis y el diseño de sistemas FDD en caso de problemas de comunicación de datos, como retardos y pérdidas. Se proponen dos técnicas para reducir estos problemas: una basada en programación dinámica y la otra en optimización. Los métodos propuestos han sido validados sobre diferentes sistemas dinámicos: control de posición de un motor de corriente continua, una planta de laboratorio y un problema de sistemas eléctricos conocido como hueco de tensión.

Hybrid fault detection and isolation in an heater bank of an HVAC system

In this work a hybrid technique that includes probabilistic and optimization based methods is presented. The method is applied, both in simulation and by means of real-time experiments, to the heating unit of a Heating, Ventilation Air Conditioning (HVAC) system. It is shown that the addition of the probabilistic approach improves the fault diagnosis accuracy.

Fault detection and isolation on a noisy nonlinear circuit

In this paper fault detection and isolation (FDI) schemes are applied in the context of the surveillance of emerging faults in an electrical circuit. The FDI problem is studied on a noisy nonlinear circuit, where both abrupt and incipient faults in the voltage source are considered. A rigorous analysis of fault detectability precedes the application of the fault detection (FD) scheme; then, the fault isolation (FI) phase is accomplished with two alternative FI approaches, proposed as new extensions of that FD approach. Numerical simulations illustrate the applicability of the mentioned schemes.

Development and improvement of protection-system algorithms for ground-fault detection and location in synchronous machines

Uno de los defectos más frecuentes en los generadores síncronos son los defectos a tierra tanto en el devanado estatórico, como de excitación. Se produce un defecto cuando el aislamiento eléctrico entre las partes activas de cualquiera de estos devanados y tierra se reduce considerablemente o desaparece. La detección de los defectos a tierra en ambos devanados es un tema ampliamente estudiado a nivel industrial. Tras la detección y confirmación de la existencia del defecto, dicha falta debe ser localizada a lo largo del devanado para su reparación, para lo que habitualmente el rotor debe ser extraído del estator. Esta operación resulta especialmente compleja y cara. Además, el hecho de limitar la corriente de defecto en ambos devanados provoca que el defecto no sea localizable visualmente, pues apenas existe daño en el generador. Por ello, se deben aplicar técnicas muy laboriosas para localizar exactamente el defecto y poder así reparar el devanado. De cara a reducir el tiempo de reparación, y con ello el tiempo en que el generador esta fuera de servicio, cualquier información por parte del relé de protección acerca de la localización del defecto resultaría de gran utilidad. El principal objetivo de esta tesis doctoral ha sido el desarrollo de nuevos algoritmos que permitan la estimación de la localización de los defectos a tierra tanto en el devanado rotórico como estatórico de máquinas síncronas. Respecto al devanado de excitación, se ha presentado un nuevo método de localización de defectos a tierra para generadores con excitación estática. Este método permite incluso distinguir si el defecto se ha producido en el devanado de excitación, o en cualquiera de los componentes del sistema de excitación, esto es, transformador de excitación, conductores de alimentación del rectificador controlado, etc. En caso de defecto a tierra en del devanado rotórico, este método proporciona una estimación de su localización. Sin embargo, para poder obtener la localización del defecto, se precisa conocer el valor de resistencia de defecto. Por ello, en este trabajo se presenta además un nuevo método para la estimación de este parámetro de forma precisa. Finalmente, se presenta un nuevo método de detección de defectos a tierra, basado en el criterio direccional, que complementa el método de localización, permitiendo tener en cuenta la influencia de las capacidades a tierra del sistema. Estas capacidades resultan determinantes a la hora de localizar el defecto de forma adecuada. En relación con el devanado estatórico, en esta tesis doctoral se presenta un nuevo algoritmo de localización de defectos a tierra para generadores que dispongan de la protección de faltas a tierra basada en la inyección de baja frecuencia. Se ha propuesto un método general, que tiene en cuenta todos los parámetros del sistema, así como una versión simplificada del método para generadores con capacidades a tierra muy reducida, que podría resultar de fácil implementación en relés de protección comercial. Los algoritmos y métodos presentados se han validado mediante ensayos experimentales en un generador de laboratorio de 5 kVA, así como en un generador comercial de 106 MVA con resultados satisfactorios y prometedores. ABSTRACT One of the most common faults in synchronous generators is the ground fault in both the stator winding and the excitation winding. In case of fault, the insulation level between the active part of any of these windings and ground lowers considerably, or even disappears. The detection of ground faults in both windings is a very researched topic. The fault current is typically limited intentionally to a reduced level. This allows to detect easily the ground faults, and therefore to avoid damage in the generator. After the detection and confirmation of the existence of a ground fault, it should be located along the winding in order to repair of the machine. Then, the rotor has to be extracted, which is a very complex and expensive operation. Moreover, the fact of limiting the fault current makes that the insulation failure is not visually detectable, because there is no visible damage in the generator. Therefore, some laborious techniques have to apply to locate accurately the fault. In order to reduce the repair time, and therefore the time that the generator is out of service, any information about the approximate location of the fault would be very useful. The main objective of this doctoral thesis has been the development of new algorithms and methods to estimate the location of ground faults in the stator and in the rotor winding of synchronous generators. Regarding the excitation winding, a new location method of ground faults in excitation winding of synchronous machines with static excitation has been presented. This method allows even to detect if the fault is at the excitation winding, or in any other component of the excitation system: controlled rectifier, excitation transformer, etc. In case of ground fault in the rotor winding, this method provides an estimation of the fault location. However, in order to calculate the location, the value of fault resistance is necessary. Therefore, a new fault-resistance estimation algorithm is presented in this text. Finally, a new fault detection algorithm based on directional criterion is described to complement the fault location method. This algorithm takes into account the influence of the capacitance-to-ground of the system, which has a remarkable impact in the accuracy of the fault location. Regarding the stator winding, a new fault-location algorithm has been presented for stator winding of synchronous generators. This algorithm is applicable to generators with ground-fault protection based in low-frequency injection. A general algorithm, which takes every parameter of the system into account, has been presented. Moreover, a simplified version of the algorithm has been proposed for generators with especially low value of capacitance to ground. This simplified algorithm might be easily implementable in protective relays. The proposed methods and algorithms have been tested in a 5 kVA laboratory generator, as well as in a 106 MVA synchronous generator with satisfactory and promising results.

Fault diagnostics and supervised testing : How fault diagnostic tools can be proactive?

The topic of fault detection and diagnostics (FDD) is studied from the perspective of proactive testing. Unlike most research focus in the diagnosis area in which system outputs are analyzed for diagnosis purposes, in this paper the focus is on the other side of the problem: manipulating system inputs for better diagnosis reasoning. In other words, the question of how diagnostic mechanisms can direct system inputs for better diagnosis analysis is addressed here. It is shown how the problem can be formulated as decision making problem coupled with a Bayesian Network based diagnostic mechanism. The developed mechanism is applied to the problem of supervised testing in HVAC systems.