Alsuwian Turki, Amin Arslan Ahmed, Maqsood Muhammad Taimoor, Qadir Muhammad Bilal, Almasabi Saleh, Jalalah Mohammed
Department of Electrical Engineering, College of Engineering, Najran University, Najran 11001, Saudi Arabia.
Department of Electrical Engineering, FAST National University of Computer and Emerging Sciences, Chiniot 35400, Pakistan.
Sensors (Basel). 2022 May 19;22(10):3864. doi: 10.3390/s22103864.
Faults frequently occur in the sensors and actuators of process machines to cause shutdown and process interruption, thereby creating costly production loss. centrifugal compressors (CCs) are the most used equipment in process industries such as oil and gas, petrochemicals, and fertilizers. A compressor control system called an anti-surge control (ASC) system based on many critical sensors and actuators is used for the safe operation of CCs. In this paper, an advanced active fault-tolerant control system (AFTCS) has been proposed for sensor and actuator faults of the anti-surge control system of a centrifugal compressor. The AFTCS has been built with a dedicated fault detection and isolation (FDI) unit to detect and isolate the faulty part as well as replace the faulty value with the virtual redundant value from the observer model running in parallel with the other healthy sensors. The analytical redundancy is developed from the mathematical modeling of the sensors to provide estimated values to the controller in case the actual sensor fails. Dual hardware redundancy has been proposed for the anti-surge valve (ASV). The simulation results of the proposed Fault-tolerant control (FTC) for the ASC system in the experimentally validated CC HYSYS model reveal that the system continued to operate in the event of faults in the sensors and actuators maintaining system stability. The proposed FTC for the ASC system is novel in the literature and significant for the process industries to design a highly reliable compressor control system that would continue operation despite faults in the sensors and actuators, hence preventing costly production loss.
过程机器的传感器和执行器经常出现故障，导致停机和过程中断，从而造成高昂的生产损失。离心压缩机（CCs）是石油和天然气、石化和化肥等过程工业中使用最多的设备。一种基于许多关键传感器和执行器的压缩机控制系统，即防喘振控制（ASC）系统，用于离心压缩机的安全运行。本文针对离心压缩机防喘振控制系统的传感器和执行器故障，提出了一种先进的主动容错控制系统（AFTCS）。AFTCS构建了一个专用的故障检测与隔离（FDI）单元，用于检测和隔离故障部件，并用与其他健康传感器并行运行的观测器模型的虚拟冗余值替换故障值。通过传感器的数学建模开发解析冗余，以便在实际传感器出现故障时为控制器提供估计值。针对防喘振阀（ASV）提出了双硬件冗余。在经过实验验证的CC HYSYS模型中，针对ASC系统的所提出的容错控制（FTC）的仿真结果表明，在传感器和执行器出现故障的情况下，系统仍能继续运行，保持系统稳定性。针对ASC系统所提出的FTC在文献中是新颖的，对于过程工业设计一个高度可靠的压缩机控制系统具有重要意义，该系统在传感器和执行器出现故障时仍能继续运行，从而防止高昂的生产损失。
