Structural analysis based sensor measurement fault diagnosis in cement industries |
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| Affiliation: | 1. Berkeley Education Alliance for Research in Singapore, Singapore 138602, Singapore;2. School of Electrical and Electronics Engineering, SASTRA University, India;3. Smarta Opti Solutions, Chennai, India;1. Science and Technology on Integrated Logistics Support Laboratory, National University of Defense Technology, Changsha 410073, China;2. College of Mechatronic Engineering and Automation, National University of Defense Technology, Changsha 410073, China;1. Structure Institute, National University of Tucumán, Av. Independencia 1800, San Miguel de Tucumán CP 4000, Argentina;2. GIDMA, Department of Civil Engineering, Regional Faculty of Córdoba, National Technological University, Maestro M. López esq. Cruz Roja, Córdoba X5016ZAA, Argentina;3. CONICET, Av. Rivadavia 1917, Buenos Aires, Argentina;1. Herbert Gleiter Institute of Nanoscience, Nanjing University of Science and Technology, Nanjing, No.200, Xiaolingwei 210094, China;2. Department of Mechanical Engineering, Howard University, Washington, D.C. 20059, USA;3. Department of Metallurgical and Materials Engineering & Centre of Nanotechnology, IIT Roorkee, Roorkee 247667, India;4. Department of Engineering Design Indian Institute of Technology Madras, Chennai 600036, India;5. Department of Mechanical and Industrial Engineering, IIT Roorkee, Roorkee 247667, India;6. Materials Science Division, Bhabha Atomic Research Center, Mumbai 40085, India |
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| Abstract: | This investigation presents a fault diagnosis methodology for detecting sensor faults in cement industries pyro processing section. It works in three steps: (a) modelling, (b) analysis, and (c) validation. In the modelling, the actual data from the cement pyro processing is used to do a correlation analysis between output and input variables. The structural model is obtained from the correlation tests. During the analysis phase the Structural analysis Tool (SaTool) is used to detect the detectability and isolability of the faults. The results of the structural analysis are validated in a cement industry using residual analysis performed using structural sensor model and real-time measurements. The main advantages of this fault diagnosis technique are: (a) it requires only correlation analysis to obtain the structural model without a detailed physical model as in other methods, (b) conclusions regarding detectability and isolability can be easily drawn during the analysis stage itself, and (c) the method is simple compared to the model-based, and data-history based methods. The effectiveness of the proposed method is illustrated using data from cement pyro processing plant and its performance is compared with model based approaches for four different types of sensor faults: (1) bias, (2) drift, (3) stuck, and (4) measurement failures. Our results demonstrate that the structural method is able to detect the sensor faults even in the presence of noisy information, and its performance is comparable with that of model based approaches without employing a physical model. |
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| Keywords: | Fault diagnosis Structural model Measurement faults Cement kiln Structural analysis SaTool |
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