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Opening Session 7th IFAC Symposium SAFEPROCESS, Barcelona, 1st July 2009

IFAC SAFEPROCESS: - History, Status, Experiences - Rolf Isermann Darmstadt University of Technology Institute of Automatic Control Darmstadt, Germany. Opening Session 7th IFAC Symposium SAFEPROCESS, Barcelona, 1st July 2009. IFAC SAFEPROCESS History Status Experiences Outlook.

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Opening Session 7th IFAC Symposium SAFEPROCESS, Barcelona, 1st July 2009

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  1. IFAC SAFEPROCESS: - History, Status, Experiences -Rolf IsermannDarmstadt University of TechnologyInstitute of Automatic ControlDarmstadt, Germany Opening Session 7th IFAC Symposium SAFEPROCESS, Barcelona, 1st July 2009

  2. IFAC SAFEPROCESS • History • Status • Experiences • Outlook

  3. On the history of IFAC SAFEPROCESS • Until 1990: fault detection and supervision treated in special sessions of symposia and congresses • 1989: Application for a Conference SAFEPROCESS by German NMO accepted • 1st Symposium SAFEPROCESS in Baden-Baden, 10-13 Sep. 1991 • Title SAFEPROCESS was selected as abbreviation of the field (similar as IFAC/IFIP Workshops SAFECOMP for computer systems) • 1991: Steering committee founded in Baden-Baden to support continuity • 1993:IFAC Technical Committee SAFEPROCESS accepted within the Application Committee of the IFAC Technical Board • 1993: Technical Board accepts IFAC SAFEPROCESS on the Masterplan for Symposia • 1994: 2nd IFAC Symposium SAFEPROCESS in Espoo, Finland: →A new Symposium series got started

  4. Preface Proceeedings 1 st IFAC-SAFEPROCESS 1991

  5. RI 1991 Preface of Preprints 1st IFAC SAFEPROCESS 1991 Baden-Baden

  6. Rolf Isermann • Bernd Freyermuth • 137 papers • 287 participants • 55 % from industry

  7. Pentti Lautala • Björn Wahlström • Tuula Ruokonen • 133 papers • 220 participants

  8. Ron J. Patton • Steve Daley • Jie Chen • 209 papers • 200 participants

  9. Josef Bokor • Andras M. Edelmayer • Csilla Banyasz • 200 papers • 200 participants

  10. Janos Gertler • Marcel Staroswiecki • N. Eva Wu • 197 papers • 175 participants

  11. J. Korbicz D.H. Zhou H.Y. Zhang 258 papers 201 partipants

  12. Janos Gertler Ron Patton Joseba Quevedo Teresa Escobet Vicenc Puig Bernardo Morcego Andreu Quesada 264 papers 292 participants (207 professionals 85 students) (26 June 09)

  13. IFAC • IFAC Technical Committee Chemical Process Control: • IFAC Workshops: Fault detection and supervision in the chemical process industries • 1992: Newark-Delaware, USA • 1995: Newcastle, UK • 1998: Solaize-Lyon, FR • 2001: Cheju, KR • IFAC Congresses: • 1990 Tallinn: 1 session • 1993: Sydney: 4 sessions • 1996: San Francisco: 9 sessions • 1999: Beijing: • 2002: Barcelona: 13 sessions • 2005: Prague: 11 sessions, • 2008: Seoul: 5 sessions + CC1, CC2

  14. IFAC SAFEPROCESS • History • Status • Experiences • Outlook

  15. IFAC Technical Committee SAFEPROCESS : • Planning and organisation of new Symposia • Foundation of International Program Committees • Selection of Guest-Countries • Design and maintenance of TC web page • TC Chairs act for 3 years, can be expanded to another 3 years • 2008: 65 members • Organisation of Sessions for IFAC Congresses • 1991- 1996: Terminology on fault detection and diagnosis • Control Engineering Practice 5 (1997), 709-719 • http://www.rtm.tu-darmstadt.de/fd_terminology.html • Technical Committee Chairs: • 1991 – 1996 Rolf Isermann • 1996 - 2002 Ron Patton • 2002 – 2008 Michel Kinnaert / Michelle. Basseville/ Jakob Stoustrup • 2008 - 2011 Jakob Stoustrup / Michel Kinnaert /Michel Verhaegen

  16. IFAC SAFEPROCESS • History • Status • Experiences • Methods • Applications • Outlook

  17. Fault Management • Hazard Classes  Features  Fault  Symptoms Feature Generation FaultDiagnosis FaultDetection FaultEvaluation Supervision w. Fault Diagnosis Decision Ope- rator Protection Supervisory Level Protec-tion Monitoring Stop Operation Alarm SignalEvaluation F Fault Change Operation Measurements [W, U] C P Reconfi-guration [U, X, Y] Control and Process Level Process and Control Mainte- nance Repair Fault-management actions

  18. FAULT- DETECTION METHODS detection with detection with multiple single signals signals and models multi-variate process signal limit trend data models models checking checking analysis used used fixed adaptive change- state parity principal spectrum neural state correla- param. Wavelet ob- equa- component thres- thresh- detection analysis networks estim. tion estim. analysis servers tions analysis hold olds methods Extract of fault detection methods

  19. IFAC SAFEPROCESS • History • Status • Experiences • Methods • Applications

  20. Research projects at IAT (33 Doctoral thesis 1981 – 2008, 50 % industry projects): • 4. Plants • Pipeline leak detection and localization liquids and gases (ethylen) • Heat exchangers (steam/water., heating boilers) • 5. Manufacturing • Feeddrive (DC-, Synchron-Mot) • Production center (MAHO MC5) • main drive, feed drives • milling, drilling, turning • Grinding machines • Industrial robot (6 axes) • 6. Automobiles • Suspension, active suspension (ABC) • Hydraulic brake system • Drive dynamic stability, over-, understeering • Fault-tolerant sensor platform • 7. Internal combustion engines • Gasoline engines • Diesel engines • 8. Fault-tolerant systems • Duplex-Asynchroneous-drivee • Duplex-valve hydraulic servo system 1. Electrical drives • DC motors • With brushes • Electronic commutation • Inductionmotors • Asynchroneous motors frequency controlled, with inverters • Universalmotors 2. Actuators • Electrical throttle • Electrical cabine pressure valve (aircraft ,BLDC) • Pneumatic cylinder- and membrane actuators • Hydraulic Servoaxis 3. Pumps • Centrifugal pumps with DC- and AC- motors • Reciprocating pump (oscillating pump) →Isermann, R.:Fault Diagnosis of Technical Processes, Springer-Verlag, Berlin, 2009/2010 Theoretical and experimental experiences in development of fault diagnososi methods

  21. - fault list: • - actuators • - process • - sensors • fault-sympt. • trees • application? • - maintenance • - fault tolerance • available • measurements • operating • conditions • - open/closed • loop • process • modeling: • - physical • - identification • - semi-physical • signal models: • - periodic, • harmonics • - ARMA • - disturbances • tests • with other • processes • robustness • issues • (process • tolerances) • signal model • based: • - Fourieranalys. • - wavelets, … • process model • based: • - paramet. estim. • - parity equations • - observers, K.F. . • process • computer • - real time • - filtering,…. • real operating • conditions • - real signals • inserting real • faults Experiments with real process Selection fault detection methods Final Softw/hardw. realization. Require- ments Process- analysis. Simulations • adjustment • to real process • and real signals • modeltypes: • - linear • - nonlinear • - time variant • test signals: • - yes: type • - no • test of • methods • combination • of methods • fault coverage • fault diagnosis: • - isolability • - classification • - inference meth. • adjustment • of: • - models • - filters • - tuning • parameters • faults: • - detecable ? • - size ? • - diagnosible ? • process: • - linearizable • - nonlinear • operation • - stationary • - dynamic • signals: • - periodic • - stochastic • kind of faults • number of • faults • fault detection • coverage • smallest • replaceable • unit • field tests • all operating • conditions • reliability ? • maintainability ? • customer • acceptance ? feedbacks for improvements Ready for use compari- son Preconditions Results Development stages for fault detection and diagnosis

  22. Outlook: Technical driving forces for SAFEPROCESS ? • Asset management → improvement of availability and economics • Maintenance on demand • Forecast of maintenance • Estimation of availability • Life cycle optimization • Fault tolerant systems → improvement of safety (and availability) • Fault tolerant sensors • Fault tolerant actuators and drives • Fault tolerant processes • Fault tolerant control • Until now: for safety relevant systems only • Development tools→ improvement of applicability • for fault detection and diagnosis methods • user friendly, with best practice approaches • Integration of analytical + heuristic information on process behavior • Combined diagnosis for continuous + discrete event processes

  23. Important issues for successful detection & diagnosis methods: • Physical/technical understanding of fault propagation to measured signals • Physical & experimental based modeling of actuators, processes and sensors • Adjustment of suitable detection methods to real faults • Experimental and engineering skill & validation of methods

  24. Fault diagnosis + fault management: wide technical applications

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