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Mohammad Javad
Khosrowjerdi
Department of
Electrical Engineering,
Sahand University of Technology,
Tabriz 51335-1996, Iran
e-mail: khosrowjerdi@sut.ac.ir
Introduction
well as sensor failures such as cutoff and freeze. By data acquainting from nonlinear MooreGreitzer simulated model, a NN as an
observer generates residual signals. It is also needed to present an
innovation algorithm for residual evaluation block due to complexity of fault and failure scenarios. Moreover, the proposed NN
demonstrates remarkable identification properties in the presence
of uncertainties and bounded external perturbations [2325].
This paper is organized as follows. First, fundamentals concerning
the MooreGreitzer model and the surge phenomenon are discussed
in Sec. 2 briefly. Sensor fault and failure different scenarios and FD
techniques are described in Sec. 3. A more detailed description of the
structure of NN as a residual generator and the proposed algorithm
for residual evaluation are presented in Sec. 4. Section 5 deals with
the proposed FD approach for the compressor, and the simulated
results are also presented. Finally, conclusions are drawn in Sec. 6.
U UT 2K1 CBW
dn
B
dU
H
W Wc0
3 U
J
1 1
1
dn lc B
2 W
2
H
3
1 U
lE Ud K1 CU 1
1
U; W; J; B
2 W
bH
2
2
dJ
U
J 2Ud Cm 1WK1
J 1
1
dn
W
4
3bH
3aH
1 mB BaW
dB
K1 CB2
dn
2 3
W
6 7
y 4U5
B
(1)
where
r
U
Ac Lc
Ud
; b 2as
; mB B 1 m
1
b
VP
bB
p
Ud 1
qbR3 Ac
UT c W; lc B lI lE
;
; K1
bB a
2IUd
Rb
K2
L c Ud
B
(2)
Fig. 4 (a) Filtered U, (b) filtered W, (c) filtered J, and (d) filtered B
yout t M:xin t
(4)
1
2
3
4
5
6
7
Fault Diagnosis
n
1X
dq yq 2
2 q1
Dwij k
dE
dwij
(5)
zk1 zk ak gk
(3)
where xin(t) and yout(t) represent the input and output variables,
respectively. The coefficients M and A denote scale and bias factors, bias is injected as an offset, and it is specified as a percentage
of the sensor average baseline in the sensor output usually. Scaling is simulated by attenuating the signal with a scaling factor.
Seven different fault or failure scenarios are considered in this
paper as Table 1. Note that additive fault is divided into two types,
namely additive ramp (AR) and additive step (A). If A 0 and
M 1 in Eq. (4), then sensor status is fault free. When A 0 and
M 0, then the sensor becomes cutoff and the sensor is out of
service. Furthermore, in the last row from Table 1, cutoff in the B
sensor imposes the control system to be unstable, because this
sensor is used in the feedback path. For safety, the compressor
emergency shuts down in this case. In the third scenario, A A1,
M 0, and y A1; in this task, the sensor output is not a function
of x and the sensor is out of service. Note that A1 has arbitrary
and suitable value. Additive and multiplicative faults appear in
the fourth scenario contemporaneously. A 0 and 0 < M < 1 in
the fifth scenario causes one to attenuate the sensor output. It is
named the loss of efficiency expression here, and in this case,
Eq. (3) can be written as follows:
Scenario
The sixth scenario shows bias additive fault in the sensor output; it is worth mentioning that all of the additive and multiplicative faults should have reasonable amplitude for guaranteeing
stability.
Result
1
0
0
0<M<1
0<M<1
1
0
0
0
A1
A>0
0
A1
A1
Fault free
Cutoff connection (failure)
Freeze (failure)
Faulty
Loss of efficiency
Bias fault
Unstable system then ESD
where dq indicates the desired network output for the qth input
pattern and yq is the actual output of the NN. Each weight is
adjusted with this rule,
Dwij k
dE
dwij
(6)
where k is a fixed coefficient, E is the error function, and wij represents the weights of the branch between the neuron j and the neuron i. The weight adjustment process is repeated until the
difference between the node output and actual output is within
some acceptable tolerance. The training of the NN has two steps:
training and testing. During the training phase, 80% of all data is
selected randomly, and then NN is trained to capture the underlying relationship between the chosen inputs and outputs. After
training, the networks are tested with the remaining 20% of all
data as test data set, which was not used for training. The following issues are to be addressed while developing the model for
residual generation in the compressor [33].
4.1 Selection of Input and Output Variables. As mentioned, J > 0 in Eq. (1) represents the rotating stone wall operating
point in the compressor. However, it is always assumed to be
equal to zero in here, due to that the machine operating point is
far from the stall region. Therefore three NNs are needed separately for residual generation. The state variables in Eq. (1) are U,
W, J, and B, which are considered the input variables for each of
_ andB_ variables are the output variables for
_ W;
the networks and U;
each of the network, respectively.
4.2 Training Data Generation. To achieve a good performance of the NN for residual generating, the training data should
represent the complete range of operating conditions of the compressor. As shown in Fig. 6, the waveform of output variable is
independent from the value of input variable Ud and only the output variable amplitude is changed with Ud.
4.3 Data Normalization. If the raw data are used in the network training, the large amount of inputs may impress the
4.5 Network Training. The backpropagation training algorithm, which propagates the error from the output layer to the hidden layer to update the weight matrix, is most commonly used for
feedforward NN. The back propagation (BP) training algorithm, in
which the weights are moved in the direction of the negative gradient, the performance function decreases most rapidly, the negative
of the gradient. An iteration of this algorithm can be written
zk1 zk ak gk
(7)
where Xn is the normalized value of the data and Xmin and Xmax
are the minimum and maximum values among all the values of
the data.
Fig. 8
(8)
Simulated Results
diagnose seven fault and failure scenarios from each other carefully. The fault and failure detection section from this algorithm
is discussed here, for brevity. Fault and failure isolation
and identification implementation have many issues and calculations; therefore, only results of fault isolation and identification
are presented in Figs. 912. The proposed FD flow chart is
presented in the Appendix. The following issues should be
regarded for the complete proposed fault and failure diagnosis
algorithm:
(1) The proposed algorithm is able to diagnose additive and
multiplicative faults from each other at any time
No
Result
M1 1
M1 0 at
11,340
M1 m
A1 0
A1 0
M2 1
M2 1
A2 0
A2 0
M3 1
M3 1
A3 0
A3 0
Free-free-free
Cutoff 11,436-free-free
A1 a
M2 m
A2 a
M3 0 at
20,550
A3 0
M1 0 at
7890
A1 0.6 at
20,760
M2 0 at
9990
A2 0
M3 0.67 at
32,700
A3 0
M1 0 at
6360
A1 0.47 at
17,700
M2 0 at
13,800
A2 0
M3 0.6 at
12,990
AR3 0.05, at
24,66016,200
M1 0.7 at
29,100
AR1 0.05 at
71107500
M2 0.35 at
7740
A2 0.64 at
18,210
M3 0.45 at
26,070
A3 4 at
10,320
M1 0.32 at
8190
A1 0.3 at
23,250
M2 0.54 at
3960
AR2 0,
A0
M3 1
A 6 at
555516,665
M1 0.62 at
26,880
AR1 0,
A0
M2 1
AR2 0.03 at
81008400
M3 1
A3 0
1
2
3
cut off at 10,052, and the B sensor has 17.3 dropping value at
33,333 in Figs. 12(a)12(c), respectively. Note that all M coefficients show amplitude reduction gain, but these gains are converted to signal amplitude drop.
The effect of FD in determination of the operating point on the
compressor curve performance practically is presented clearly. In
Fig. 13, the operating point is A1 initially and it is supposed the
actual one. Incipient additive fault in the U sensor with amplitude
0.55 at 7279 forces the operating point to A2 as row 6 in Table 2.
Multiplicative fault in the pressure sensor with amplitude 0.45
shifts the operating point to A3 at 7750. The B sensor fault at
10,699 with 11 m/se value shifts A3 to A4. Subsequently, the
operating point is transferred to A5, A6, and A7 due to other
faults. The compressor control system considers the mentioned
points as real and actual points and acts according to them,
whereas the actual operating point is only A1.
6
Fig. 13 FD in compressor operating point determining
Conclusion
In this paper, we have investigated the problem of fault diagnosis, which is defined as the problem of fault detection and fault
isolation of the industrial compressor. We have presented a novel
approach for quick compressor surge determination by NN for
proposing our fault detection and isolation schemes. Sensor noises
have been eliminated within designed filters, and one should note
that the results presented are obtained in the presence of noisy
measurements. Our proposed fault diagnosis flow chart is presented in the Appendix. Simulation results corresponding to different faulty scenarios are presented and the results are
summarized in Table 2, showing satisfactory fault isolation performance by using our proposed solutions. Finally, fault diagnosis
results were combined within the compressor operating point
detection procedure.
Appendix
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