Advanced

Batch Control and Diagnosis

Olsson, Rasmus LU (2005) In PhD Theses TFRT-1073.
Abstract
Batch processes are becoming more and more important in the chemical process industry, where they are used in the manufacture of specialty materials, which often are highly profitable. Some examples where batch processes are important are the manufacturing of pharmaceuticals, polymers, and semiconductors.



The focus of this thesis is exception handling and fault detection in batch control. In the first part an internal model approach for exception handling is proposed where each equipment object in the control system is extended with a state-machine based model that is used on-line to structure and implement the safety interlock logic. The thesis treats exception handling both at the unit supervision level and at the... (More)
Batch processes are becoming more and more important in the chemical process industry, where they are used in the manufacture of specialty materials, which often are highly profitable. Some examples where batch processes are important are the manufacturing of pharmaceuticals, polymers, and semiconductors.



The focus of this thesis is exception handling and fault detection in batch control. In the first part an internal model approach for exception handling is proposed where each equipment object in the control system is extended with a state-machine based model that is used on-line to structure and implement the safety interlock logic. The thesis treats exception handling both at the unit supervision level and at the recipe level. The goal is to provide a structure, which makes the implementation of exception handling in batch processes easier. The exception handling approach has been implemented in JGrafchart and tested on the batch pilot plant Procel at Universitat Politècnica de Catalunya in Barcelona, Spain.



The second part of the thesis is focused on fault detection in batch processes. A process fault can be any kind of malfunction in a dynamic system or plant, which leads to unacceptable performance such as personnel injuries or bad product quality. Fault detection in dynamic processes is a large area of research where several different categories of methods exist, e.g., model-based and process history-based methods. The finite duration and non-linear behavior of batch processes where the variables change significantly over time and the quality variables are only measured at the end of the batch lead to that the monitoring of batch processes is quite different from the monitoring of continuous processes. A benchmark batch process simulation model is used for comparison of several fault detection methods. A survey of multivariate statistical methods for batch process monitoring is performed and new algorithms for two of the methods are developed. It is also shown that by combining model-based estimation and multivariate methods fault detection can be improved even though the process is not fully observable. (Less)
Please use this url to cite or link to this publication:
author
supervisor
opponent
  • Professor Jørgensen, Sten Bay, Department of Chemical Engineering, Technical University of Denmark (DTU)
organization
publishing date
type
Thesis
publication status
published
subject
keywords
Multivariate Statistical Analysis, State and Parameter Estimation, Dynamic Models, Fault Detection, Exception Handling, Recipe, S88, Batch Control, PCA, Automation, robotics, control engineering, Automatiska system, robotteknik, reglerteknik
in
PhD Theses
volume
TFRT-1073
pages
244 pages
publisher
Department of Automatic Control, Lund Institute of Technology, Lund University
defense location
Room M:B, the M-building, Ole Römers väg 1, Lund Institute of Technology
defense date
2005-06-17 10:15
ISSN
0280-5316
language
English
LU publication?
yes
id
fb1a7820-e5fb-4216-ad72-a5c889b61f9e (old id 24559)
date added to LUP
2007-06-01 07:05:25
date last changed
2016-09-19 08:44:59
@phdthesis{fb1a7820-e5fb-4216-ad72-a5c889b61f9e,
  abstract     = {Batch processes are becoming more and more important in the chemical process industry, where they are used in the manufacture of specialty materials, which often are highly profitable. Some examples where batch processes are important are the manufacturing of pharmaceuticals, polymers, and semiconductors.<br/><br>
<br/><br>
The focus of this thesis is exception handling and fault detection in batch control. In the first part an internal model approach for exception handling is proposed where each equipment object in the control system is extended with a state-machine based model that is used on-line to structure and implement the safety interlock logic. The thesis treats exception handling both at the unit supervision level and at the recipe level. The goal is to provide a structure, which makes the implementation of exception handling in batch processes easier. The exception handling approach has been implemented in JGrafchart and tested on the batch pilot plant Procel at Universitat Politècnica de Catalunya in Barcelona, Spain.<br/><br>
<br/><br>
The second part of the thesis is focused on fault detection in batch processes. A process fault can be any kind of malfunction in a dynamic system or plant, which leads to unacceptable performance such as personnel injuries or bad product quality. Fault detection in dynamic processes is a large area of research where several different categories of methods exist, e.g., model-based and process history-based methods. The finite duration and non-linear behavior of batch processes where the variables change significantly over time and the quality variables are only measured at the end of the batch lead to that the monitoring of batch processes is quite different from the monitoring of continuous processes. A benchmark batch process simulation model is used for comparison of several fault detection methods. A survey of multivariate statistical methods for batch process monitoring is performed and new algorithms for two of the methods are developed. It is also shown that by combining model-based estimation and multivariate methods fault detection can be improved even though the process is not fully observable.},
  author       = {Olsson, Rasmus},
  issn         = {0280-5316},
  keyword      = {Multivariate Statistical Analysis,State and Parameter Estimation,Dynamic Models,Fault Detection,Exception Handling,Recipe,S88,Batch Control,PCA,Automation,robotics,control engineering,Automatiska system,robotteknik,reglerteknik},
  language     = {eng},
  pages        = {244},
  publisher    = {Department of Automatic Control, Lund Institute of Technology, Lund University},
  school       = {Lund University},
  series       = {PhD Theses},
  title        = {Batch Control and Diagnosis},
  volume       = {TFRT-1073},
  year         = {2005},
}