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1,4,5
Department of Electrical and Computer Engineering, Pusan National University, Busan, 46241, South Korea
{garden03121, parkjh4, sskim5}@pusan.ac.kr
2
Technical Solution Center, Technology & Information Department, Korea East-West Power Co., Ltd., Dangjin,
Chungcheongnam-do, 31700, South Korea
zanggre250@ewp.co.kr
3
CTO, XEONET Co., Ltd., Seongnam, Gyeonggi-do, 13216, South Korea
joeyoo@xeonet.co.kr
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ANNUAL CONFERENCE OF THE PROGNOSTICS AND HEALTH MANAGEMENT SOCIETY 2016
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T
X TP T Tˆ T Pˆ ˆ ˆ T TP T ,
P TP (6)
Multivariate training
3. SUMMARY OF THE TARGET SYSTEM: 250 MW COAL-
data matrix, X FIRED POWER PLANT
Unseen data In this study, the target system is a 250 MW coal-fired TPP.
z-score standardization
vector, xnew Fig. 2 shows an example of distributed control system (DCS)
screen. An unplanned shutdown data due to boiler tube
Calculate covariance
matrix, Σ
Calculate Q statistic of xnew leakage was collected from the DCS and is used to
demonstrate the performance.
Calculate eigenvalues λj and Calculate EWMA
eigenvectors pj (j = 1,..., m)
3.1. Coal-fired thermal power plant
Q ≥ Qα or
Determine the retained
EWMA ≥ Qα
In the coal-fired power plant, after transforming feedwater
number of PCs (i.e., l)
into steam by thermal energy produced from combustion of
Yes
Alarm signal
bituminous coal, electricity is generated by driving steam
Calculate threshold value, Qα
generation turbine and generator. Fig. 3 shows a simplified schematic
diagram of the target TPP. (Yu, Jang, Yoo, Park, and Kim,
P, l, Qα 2016). Steam boiler raises steam by heating feedwater using
Fig. 1. PCA-based fault detection procedures. thermal energy converted from fossil fuel. The steam boiler
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ANNUAL CONFERENCE OF THE PROGNOSTICS AND HEALTH MANAGEMENT SOCIETY 2016
Boiler SH
3-phase
3.2. Boiler tube leakage
Failure of one or more tubes in the boiler can be detected by
LP TBN 1
LP TBN 2
HP TBN
IP TBN
RH
G Gen.
sound and either by an increase in make-up water
Evap.
Drum
BFP COP
fireside corrosion and/or erosion, stress rupture due to
HP FW LP FW
Heater Heater overheat and creep, vibration-induced and thermal fatigue
Abbreviations cracking, and defective welds (Oakey, 2011).
Evap. Evaporator BFP Boiler feedwater pump
SH Superheater COP Condensate pump
RH Reheater Con. Condenser The tube leakage from a pin-hole could be tolerated due to
Eco. Economizer HP FW High pressure feedwater
HP TBN High pressure turbine LP FW Low pressure feedwater the adequate margin of feedwater and the leakage can be
IP TBN Intermediate pressure turbine Gen. Generator
LP TBN Low pressure turbine Ext. Extraction corrected after suitable scheduled maintenance. However, if
Fig. 3. Simplified schematic diagram of the coal-fired the boiler is continuously operated with the leakage, much
power plant. pressurized fluid leaks out eventually and severe damage to
neighboring tubes occurs. The tube leakage of boiler,
follows the thermodynamic steam cycle, i.e., Rankine cycle, superheater and reheater could give rise to serious decline of
which is a practical implementation of the ideal Carnot cycle efficiency. In the short term, the tube leakage of superheater
(Flynn, 2003). Steam, an important medium to produce and reheater is more fatal than that of boiler. When severe
mechanical energy, can be generated from abundant water, tube leakage happens, it is difficult to maintain the level of
does not react much with materials of the power plant the boiler drum properly. If leaking water is spilled into
equipment and is stable at the required operation temperature furnace, combustion of coal is disturbed. In these cases, the
in the power plant (Raja, 2006). plant should be shut down immediately.
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decided as 8 by eq. (5). The first eight PCs can capture 93.18
3.5
percent of entire variations. As described in eq. (8), Q statistic
3
is calculated by only eight retained eigenvectors. After
Eigenvalue 2.5
deciding the retained number of PCs, Qα is calculated by eq.
2
(9). Fig. 6 shows the histogram of Q statistics for the training
1.5
samples and Qα for fault detection. In Fig. 6, the value for α
1
is set as 0.05 and the calculated value of Qα is 2.5742 and
0.5
indicated by a vertical dashed red line.
0
1 2 3 4 5 6 7 8 9 10 11 12 13
Principal component (PC)
4.2. Results of the test step
Fig. 4. Eigenvalues of each principal component.
In this subsection, the results of fault detection using the
100 PCA-based method are presented. EWMA is used to generate
90 alarm signals and its window size is set as 6, i.e., the six most
80 recent Q statistics are considered. The detection indices are
CPV (%)
500
monitored variables for boiler tube leakage detection are In this subsection, using four measures, the results of
carefully selected by domain experts. After applying training performance comparisons for both indices, i.e., without and
step described in Fig. 1 to the training samples, the with EWMA, are presented. The four performance measures,
performance is validated using the test samples. i.e., accuracy (ACC), sensitivity (SEN), specificity (SPE),
and precision (PRE), are defined as (Han, Kamber, and Pei,
2011)
4.1. Results of the training step
The standardized fault-free training data is used to calculate TP TN
covariance matrix, eigenvectors, the proper number of PCs ACC , (10)
PN
and Qα. Fig. 4 shows eigenvalues that correspond to 13 PCs.
TP
As shown in Fig. 4, the PCs from first to third capture SEN , (11)
approximately 60 percent of multivariate data information, P
i.e., important variations, while the PCs from 10th to 13th TN
SPE , (12)
contain lower than 5 percent of the information. In other N
words, most important variations can be captured by several
TP
PCs and dimensionality reduction is also possible. In this PRE , (13)
paper, CPV method is employed for determining the proper TP FP
number of PCs and Fig. 5 shows the results of the CPV
method. In Fig. 5, CPVth is set as 90% and indicated by where
horizontal dashed red line. The retained number of PCs is
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10
10
12 hours
Table 2. Performance comparisons (with EWMA vs.
11
10
10
Fault
region without EWMA).
ACC SEN SPE PRE
statistic
Q statistic
00
10
10
without
Q 0.8786 0.6167 0.9122 0.4744
Q
-1-1
10
10 EWMA
Q of Q EWMA
QQ
Failure
Failuretime
time
with EWMA 0.9412 0.7583 0.9647 0.7339
-2 -2
10
10
00 144
144 288
288 432
432 576
576 720
720 864
864 1008 1152 1296 Improvements 7.12% 22.96% 5.76% 54.70%
Time
Time
(a)
2
1.4
1.4
10
Alarm
TN the number of samples that were correctly
Alarm
1.2
1.2
1
Failuretime
Failure time determined as normal samples;
10 11
signal
0.8
0.8
10
0
0.6
0.6
as fault samples;
Alarm
0.4
0.4 Q FN the number of samples that were incorrectly
-1
100.2 EWMA of Q
0.2 Q determined as normal samples.
00
-2 Failure time
10 0
0 144
144 288
288 432
432 576
576
Time
720
720 864
864 1008
1008 1152 1296
1152 1296 Table 2 lists the comparison results of fault detection
Time
performance using the four measures. It can be seen from the
(b)
1.4 table that the results with EWMA show better performance
Alarm
1.2 Failure time than those without EWMA. The fact that both SEN and SPE
1 are improved shows that the method with EWMA achieves
Alarm signal
0.8
better performance in both normal and abnormal regions. If
0.6
0.4
Q statistic is used separately for alarm signal generation, it is
0.2 assumed that those of present and past are independent each
0 other; false alarm rate may increase because the trend of Q
0 144 288 432 576 720 864 1008 1152 1296
Time statistic is ignored. When EWMA of Q statistics is employed
(c) for detection index, false alarms were reduced since the
Fig. 7. (a) Q statistics and EWMA for the test samples tendency of Q statistics can be considered.
on a semi-logarithmic scale (b) alarm signal without
EWMA (c) alarm signal with EWMA. 5. CONCLUSION
10
2
10
2
In this paper, PCA and EWMA were combined for detecting
2 hours boiler tube leakage in TPP. To illustrate the performance, we
10
11
10 applied the fault detection method to unplanned shutdown
statistic
Q statistic
00
dataset collected from DCS of target TPP. The experimental
10
10
results showed that the method can detect failure symptoms
Q
Q
10
-1-1
10 EWMA of Q right before the shutdown successfully. Furthermore, fault
Q
0.8
0.8 unplanned shutdown dataset was used. In future research,
0.6
0.6 various shutdown dataset will be collected; the proposed
Alarm
0.4
0.4 method will be applied to the collected dataset and field
0.2
0.2
application possibilities will be also examined. Moreover, we
00
912
912 936
936 960
960 984
984 1008
1008 1032
1032 1056
1056 1080
1080
will develop a method that can consider different operating
Time
Time modes (e.g., free governor mode) for fault detection and
(b) diagnosis.
Fig. 8. Enlargement of failure symptom region in Fig. 7
(a): (a) Q statistic and EWMA; (b) alarm signal with ACKNOWLEDGEMENT
EWMA.
This work was supported by the Energy Efficiency &
P the number of fault samples; Resources Core Technology Program of the Korea Institute
N the number of normal samples; of Energy Technology Evaluation and Planning (KETEP)
TP the number of samples that were correctly detected granted financial resource from the Ministry of Trade,
as fault samples; Industry & Energy, Republic of Korea (No. 20151110200040)
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Solution Center, Korea East-West Power Co., Ltd. His Pusan National University, Busan, Korea. His research
research interests include multi-variable control, data mining interests include intelligent systems applications to power
and fault diagnosis, etc. systems. Dr. Park has been a member of the IEEE Power
Engineering Society.
Jaeyeong Yoo received the B.S. degrees in Electrical
Engineering from Yonsei University, Korea, in 1982. He has Sungshin Kim received his B.S. and M.S. degrees in
been a senior researcher at LSIS Co., Ltd. from 1983 to 1991. Electrical Engineering from Yonsei University, Korea, in
He is currently a chief technology officer (CTO) at the 1984 and 1986, respectively, and his Ph.D. degree in
XEONET Co., Ltd. His research interests include process Electrical Engineering from the Georgia Institute of
controller design, fault diagnosis and prognosis, etc. Technology, USA, in 1996. He is currently a professor at the
Electrical Engineering Department, Pusan National
June Ho Park received the B.S., M.S. and Ph.D. degrees
University. His research interests include fuzzy logic controls,
from Seoul National University, Seoul, Korea in 1978, 1980,
neuro fuzzy systems, neural networks, robotics, signal
and 1987, respectively, all in electrical engineering. He is
analysis, and intelligent systems.
currently a Professor at the School of Electrical Engineering,