Abstract
One of the key issues in modelling for fault detection is how to accommodate the level of detail of the model description to suit the diagnostic requirements. The paper addresses a two-stage modelling concept to an industrial heat exchanger, which is located in a tyre factory. Modelling relies on both, prior knowledge and recorded data. During the identification procedure, the estimates of continuous model parameters are calculated by the least squares method and the state variable filters (SVF). It is shown that the estimates are largely invariant of the bandwidth of the SVFs. This greatly reduces the overall modelling effort and makes the whole concept applicable even for less experienced users. The main issues of the modelling procedure are emphasized. Based on the process model, a simple detection system is derived. An excerpt of the results obtained on operating records is given.
Highlights
Model-based condition monitoring of industrial processes aims at early revelation of degradations in process equipment and instrumentation
A sensible process model acts as an additional virtual instrument, which contributes to a higher quality of production and better safety
The work represents part of the prototyping design of a condition monitoring system for the process of incineration of vulcanisation gasses located in a tyre factory [6]
Summary
Model-based condition monitoring of industrial processes aims at early revelation of degradations in process equipment and instrumentation. This paper deals with the design of a fault detector for a heat exchanger as a possible alternative to some other approaches [7] to [11]. The model structure is derived up to unknown parameters by strongly relying on reasoning from first principles. After taking the available instrumentation into consideration, the set of prior assumptions and the diagnostic requirements the modelling procedure ended up with a continuous-time model linear in parameters. This observation deserves attention since the choice of bandwidth, as a design parameter, turns out to be quite an easy task This is believed to be one of the contributions of the paper. The model-based diagnostic algorithm is designed to run on-line as an external C module of SCADA. The derivation of the model structure and the parameter estimation approach is described in the first section.
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