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Optimal Automated Process Fault Analysis

ISBN: 978-1-118-37231-9
224 pages
January 2013
Optimal Automated Process Fault Analysis (111837231X) cover image

Tested and proven strategy to develop optimal automated process fault analyzers

Process fault analyzers monitor process operations in order to identify the underlying causes of operational problems. Several diagnostic strategies exist for automating process fault analysis; however, automated fault analysis is still not widely used within the processing industries due to problems of cost and performance as well as the difficulty of modeling process behavior at needed levels of detail.

In response, this book presents the method of minimal evidence (MOME), a model-based diagnostic strategy that facilitates the development and implementation of optimal automated process fault analyzers. MOME was created at the University of Delaware by the researchers who developed the FALCON system, a real-time, online process fault analyzer. The authors demonstrate how MOME is used to diagnose single and multiple fault situations, determine the strategic placement of process sensors, and distribute fault analyzers within large processing systems.

Optimal Automated Process Fault Analysis begins by exploring the need to automate process fault analysis. Next, the book examines:

  • Logic of model-based reasoning as used in MOME
  • MOME logic for performing single and multiple fault diagnoses
  • Fuzzy logic algorithms for automating MOME
  • Distributing process fault analyzers throughout large processing systems
  • Virtual SPC analysis and its use in FALCONEER™ IV
  • Process state transition logic and its use in FALCONEER™ IV

The book concludes with a summary of the lessons learned by employing FALCONEER™ IV in actual process applications, including the benefits of "intelligent supervision" of process operations.

With this book as their guide, readers have a powerful new tool for ensuring the safety and reliability of any chemical processing system.

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Table of Contents




Chapter 1. Motivations for Automating Process Fault Analysis

1.1  Introduction

1.2  CPI Trends to Date

1.3  The Changing Role for the Process Operators in Plant Operations

1.4  Methods Currently Used to Perform Process Fault Management

1.5  Limitations of Human Operators in Performing Process Fault Management

1.6  The Role of Automated Process Fault Analysis

1.7  Anticipated Future CPI Trends

1.8  Process Fault Analysis Concept Terminology

Chapter 2. Method of Minimal Evidence: Model-Based Reasoning

2.1 Overview

2.2 Introduction

2.3 Method of Minimal Evidence Overview

2.4 Verifying the Validity and Accuracy of the Various Primary Models

2.5 Summary

Chapter 3. Method of Minimal Evidence: Diagnostic Strategy Details

3.1 Overview

3.2 Introduction

3.3 MOME Diagnostic Strategy

3.4 A General Procedure for Developing and Verifying Competent Model-based

3.5 MOME SV & PFA Diagnostic Logic Compiler Motivations

3.6 MOME Diagnostic Strategy Summary

Chapter 4. Method of Minimal Evidence: Fuzzy Logic Algorithm

4.1 Overview

4.2 Introduction

4.3 Fuzzy Logic Overview

4.4 MOME Fuzzy Logic Algorithm

4.5 Certainty Factor Calculation Review

4.6 MOME Fuzzy Logic Algorithm Summary

Chapter 5. Method of Minimal Evidence: Criteria for Shrewdly Distribution Fault Analyzers and Strategic Process Sensor Placement

5.1 Overview

5.2 Criteria for Shrewdly Distributing Process Fault Analyzers

5.3 Criteria for Strategic Process Sensor Placement

Chapter 6. Virtual SPC Analysis and Its Routine Use in Falconeer™ IV

6.1 Overview

6.2 Introduction

6.3 EWMA Calculations and Specific Virtual SPC Analysis Configurations

6.4 Virtual SPC Alarm Trigger Summary

6.5 Virtual SPC Analysis Conclusions

Chapter 7. Process State Transistion Logic and Its Routine Use in Falconeer™ IV

7.1 Temporal Reasoning Philosophy

7.2 Introduction

7.3 State Identification Analysis Currently Used in Falconeer™ IV

7.4 State Identification Analysis Summary

Chapter 8. Conclusions

8.1 Overview

8.2 Summary of the MOME Diagnostic Strategy

8.3 FALCON, FALCONEER and FALCONEER™ IV Actual KBS Application Performance Results

8.4 FALCONEER™ IV KBS Application Project Procedure

8.5 Optimal Automated Process Fault Analysis Conclusions

Appendix A. Various Diagnostic Strategies for Automating Process Fault Analysis

Appendix B. The Falcon Project

Appendix C. Process State Transition Logic Used by the Original Falconeer KBS

Appendix D. Falconeer™ IV Real-Time Suite Process Performance Solutions Demo Description

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