Diagnose de falhas e gestão de alarmes em sistemas de instrumentação e controle industriais.

Abstract

This work presents solutions for detecting, diagnosing and mitigating of failures in industrial processes, the solutions were implemented in MATLAB-Simulink®. The first solution is an approach for detection and identification of fault in industrial processes type white-box, making use of techniques based models integrated for anomaly detection, a decision logic with fixed thresholds to classify and identify damaged component and mitigation failure uses a module fault tolerant controller which the severity of the fault and its logical signal for reprogramming of the control law. The proposed approach is applied to a level and temperature plant. The second strategy intended to processes type black box, using the process history for the monitoring of abnormal events. The detection, identification and reconstruction process failures are computed by Principal Component Analysis (PCA); the detection is done through τ2 e Q statistics; the identification is made by checking the contribution of process variables in the model PCA at the time of occurrence of failure and the reconstruction is carried out by the correction vector of samples, using the magnitude value of the fault and the direction of the fault. The proposed approach is applied to Fractionator column crude oil (Shell Process). The third strategy describes a system of monitoring of abnormal events considering the process energy (energy variables), in other words, the energy information contained in measured signals. Its implementation is need to the energy signature of the process, computing input, output and consume energy intake by the process, the energy efficiency of unit and actions to optimize energy involved in procedural unit. This system diagnose interact with statistical monitoring system (PCA) to reduce the occurrence of false alarm or loss alarm monitoring system of the unit, giving more reliability to operator of the process. This strategy was evaluated for an atmospheric fractionator tower. It also proposes a methodology designer adaptive thresholds operational changes, organized a strategic policy management alarms. By the end of work will be presented the technical specifications of software fault monitoring and alarms management. The software will gather all the strategies developed in one product. The software should be integrated into the plant supervisory, assisting in operation and routine maintenance of the plant supporting the operator while minimizing unscheduled shutdowns. The main contributions are: methodological plan thresholds for characterizing adaptive, plan methodology for characterizing the initial model PCA, PCA as a tool for project evaluation instrumentation, strategy for energy signature of process unit.