R. I. TU Darmstadt IFAC SAFEPROCESS: - History, Status, Experiences - Rolf Isermann 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

R. I. TU Darmstadt IFAC SAFEPROCESS 1.History 2.Status 3.Experiences 4.Outlook

R. I. TU Darmstadt O 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, Sep –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

R. I. TU Darmstadt Preface Proceeedings 1 st IFAC-SAFEPROCESS 1991

R. I. TU Darmstadt Preface of Preprints 1st IFAC SAFEPROCESS 1991 Baden-Baden RI 1991

R. I. TU Darmstadt Rolf Isermann Bernd Freyermuth 137 papers 287 participants 55 % from industry

R. I. TU Darmstadt Pentti Lautala Björn Wahlström Tuula Ruokonen 133 papers 220 participants

R. I. TU Darmstadt Ron J. Patton Steve Daley Jie Chen 209 papers 200 participants

R. I. TU Darmstadt Josef Bokor Andras M. Edelmayer Csilla Banyasz 200 papers 200 participants

R. I. TU Darmstadt Janos Gertler Marcel Staroswiecki N. Eva Wu 197 papers 175 participants

R. I. TU Darmstadt Beijing, P.R. China August 29-September 1,2006 6th IFAC Symposium on Fault Detection, Supervision and Safety of Technical Processes J. Korbicz D.H. Zhou H.Y. Zhang 258 papers 201 partipants

R. I. TU Darmstadt 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)

R. I. TU Darmstadt IFAC O 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 O 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

R. I. TU Darmstadt IFAC SAFEPROCESS 1.History 2.Status 3.Experiences 4.Outlook

R. I. TU Darmstadt O 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 – : Terminology on fault detection and diagnosis Control Engineering Practice 5 (1997), –Technical Committee Chairs: 1991 – 1996 Rolf Isermann Ron Patton 2002 – 2008 Michel Kinnaert / Michelle. Basseville/ Jakob Stoustrup Jakob Stoustrup / Michel Kinnaert /Michel Verhaegen

R. I. TU Darmstadt IFAC SAFEPROCESS 1.History 2.Status 3.Experiences MethodsMethods ApplicationsApplications 4.Outlook

R. I. TU Darmstadt Fault Management Fault-management actions Ope- rator Ope- rator F Fault Alarm Change Operation Change Operation Reconfi- guration Decision  Hazard Classes Fault Evaluation  Fault Fault Diagnosis  Symptoms Fault Detection Protection Signal Evaluation Stop Operation Stop Operation [W, U] C C P P [U, X, Y] Feature Generation Feature Generation  Features Mainte- nance Mainte- nance Repair Process and Control Measurements Control and Process Level Supervision w. Fault Diagnosis Protec- tion Monitoring Supervisory Level

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

R. I. TU Darmstadt IFAC SAFEPROCESS 1.History 2.Status 3.Experiences MethodsMethods ApplicationsApplications

R. I. TU Darmstadt Research projects at IAT (33 Doctoral thesis 1981 – 2008, 50 % industry projects): 1. Electrical drives O DC motors With brushes Electronic commutation O Inductionmotors Asynchroneous motors frequency controlled, with inverters O Universalmotors 2. Actuators O Electrical throttle O Electrical cabine pressure valve (aircraft,BLDC) O Pneumatic cylinder- and membrane actuators O Hydraulic Servoaxis 3. Pumps O Centrifugal pumps with DC- and AC- motors O Reciprocating pump (oscillating pump) 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 → Isermann, R.: Fault Diagnosis of Technical Processes, Springer-Verlag, Berlin, 2009/2010 Theoretical and experimental experiences in development of fault diagnososi methods

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

R. I. TU Darmstadt Outlook: Technical driving forces for SAFEPROCESS ? 1.Asset management→ improvement of availability and economics Maintenance on demand Forecast of maintenance Estimation of availability Life cycle optimization 2.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 3.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

R. I. TU Darmstadt O Important issues for successful detection & diagnosis methods: 1.Physical/technical understanding of fault propagation to measured signals 2.Physical & experimental based modeling of actuators, processes and sensors 3.Adjustment of suitable detection methods to real faults 4.Experimental and engineering skill & validation of methods

R. I. TU Darmstadt Fault diagnosis + fault management: wide technical applications