Jan Maciej Kościelny

• Prof. DSc PhD Eng
• Warsaw University of Technology

This paper addresses the problem of assessing fault distinguishability of faults. Fault distinguishability is understood as the ability of a diagnostic system to isolate faults. The objective of diagnosis is the early detection and accurate isolation of the faults that have occurred. The accuracy of diagnosis depends on the fault distinguishability...

This article deals with the cyber security of industrial control systems. Methods for detecting and isolating process faults and cyber-attacks, consisting of elementary actions named “cybernetic faults” that penetrate the control system and destructively affect its operation, are analysed. FDI fault detection and isolation methods and the assessmen...

The genesis of the proposed fault isolation approach was the belief that the added value may be achieved through the synthesis of various approaches. In this paper, we propose a new method of fault isolation, which promises the achievement of a favorable effect of synergy. Principally, the proposed approach merges a fault isolation system (FIS) wit...

This paper aims to develop a method for detecting intrusions into the control system, consisting of malicious modifications of the control algorithm or its parameters. Data from the control loops are routinely collected and archived. Therefore we propose a data-based diagnosis method consisting of modelling the controller using data from normal ope...

This article concerns the detection of cyberattacks in industrial installations. A comprehensive experimental stand, and any associated simulator, have been developed in the Institute of Automatic Control and Robotics, Warsaw University of Technology. This article focuses on the simulator, its properties and its functionalities. The simulator can w...

This paper is concerned with the issue of the diagnostics of process faults and the detection of cyber-attacks in industrial control systems. This problem is of significant importance to energy production and distribution, which, being part of critical infrastructure, is usually equipped with process diagnostics and, at the same time, is often subj...

The paper proposes an original, comprehensive, and methodically consistent graph theory-based approach to the description of the diagnosed process and the diagnosing system. The main baseline of the presented approach is the dichotomous approach to diagnosing. It involves a separate description of both the process and the diagnostic system. This ap...

The paper concerns a significant problem in the diagnostics of industrial processes, which is the need to achieve high fault distinguishability. High distinguishability results in the generation of precise diagnoses that enable making appropriate security decisions. In the known approaches, the efforts to obtain high distinguishability are focused...

The paper is aimed to discuss the problem of fault isolation robustness. According to the authors, this problem has been so far underestimated and poorly discussed in the community of process diagnostics. It was pointed out that the lack of robustness of fault isolation maybe one of the main reasons limiting the broader application of advanced diag...

This paper reports on development of a laboratory set-up, for testing the concept and the components of Industry 4.0 enabled mechatronic system. A simple mock manufacturing lane is connected to a collaborating robot. There are three different programmable logic controllers (PLC) and various other elements which need to talk to each other using a va...

The primary aim of this paper is the comparative study of fault distinguishability properties of model-based fault detection and isolation approaches. We reviewed and compared diagnostic approaches based on the diagnostic signals-faults relationship. Together, five different approaches to diagnosing were examined based on the example of a three-tan...

A diagnosis based on Bayesian theory requires knowledge of the a priori and conditional probabilities of the states of the system being diagnosed. The a priori probabilities are frequently provided nowadays by the manufacturers of these systems. In turn, the probabilities of conditional observations are, as a rule, not available. The question arise...

The paper analyses the research problem of conducting diagnostic reasoning for dynamic objects to eliminate the possibility of formulating false diagnoses resulting from different delays of the symptoms related to a particular fault while simultaneously striving to obtain high distinguishability. The research aimed to develop a new diagnostic infer...

The fault compensation effect sets an important and up-to-date unsolved theoretical and practical problem for diagnostics of processes. Compensation of influences of faults on residual values has a significant impact on the diagnosis. On the one hand, there is a view that model-based diagnostics does not allow for the fault isolation for which a fa...

Basic problems of on-line diagnostics of large-scale industrial processes have been characterized, as well as the methods aimed at solving them, focusing on the authors results obtained in the area of fault isolation. Particular attention was given to fault distinguishability, multiple faults isolation, inference methods of uncertain signals, decom...

The paper discusses issues related to the adaptation of diagnostic systems to the protection of industrial control systems (ICS) against cyber threats. Typical methods of attacking industrial systems are presented, along with a brief description of exemplary attacks. The potential consequences of attacks on both the operation of supervised industri...

A comprehensive characterization of four selected fault distinguishability methods is presented herein. All considered methods are derived from structural residual approaches referring to model-based diagnostics. In particular, these methods are based on a binary diagnostic matrix, fault isolation system, sequences of symptoms, and their combinatio...

Measurements play a crucial role in diagnosis of industrial processes. The main aim of this paper is to discuss selected problems connected with the role of measurements in model-based diagnosis. The issue of the separation of the diagnostics of measuring instruments and process diagnosis is discussed. The idea of self-diagnosable sensors of single...

Cybercrime becomes a real problem in the everyday operation of production plants, industrial control systems, and other technical devices. The purpose of this article is to demonstrate that on-line diagnostics is an effective way to recognize cyberattacks. The security assurance system against cyberattacks for Industrial Control Systems is layered....

The idea of fuzzy inference approach to fault diagnosis in decentralized, single-level diagnostic structures is introduced in this paper. This approach is particularly intended for large scale industrial systems. The novel and practicable on-line fuzzy fault isolation approach in single-level structure is proposed and discussed. The fuzzy approach...

This book highlights the latest achievements concerning the theory, methods and practice of fault diagnostics, fault tolerant systems and cyber safety. When considering the diagnostics of industrial processes and systems, increasingly important safety issues cannot be ignored. In this context, diagnostics plays a crucial role as a primary measure o...

The paper is aimed at presenting a study of the main limitations and problems influencing the robustness of diagnostic algorithms used in diagnostics of complex chemical processes and to present the selected exemplary solutions of how to increase it. The five major problems were identified in the study. They are associated with: uncertainties of fa...

The novel and practicable on-line fuzzy fault isolation approach is proposed and discussed in this paper. This approach refers to proposition of diagnosing in decentralized two-level diagnostic structure. The idea of the proposed diagnostic structure is described in details as well as depicted in examples. It is particularly foreseen for applicatio...

Decomposition and decentralization of diagnosis in large scale systems decrease the need for computational and communication resources, and can speed up the overall diagnosis process. Local diagnosers are simpler and easier to build and understand. In this paper we propose simple method for diagnostic system decomposition, minimizing interconnectio...

This paper principally discusses the similarities and differences between medical and process diagnostics. The main aim of this paper is to headline those methodological achievements of the diagnostics of processes that, when implemented, may push forward development of automatized diagnostic systems intended for medical applications. First, the sp...

The article presents the tasks and structure of an IAPS IT system supporting the security system in plants posing a risk of a major industrial accident. The operation of the system consists in collecting digital documentation, as well as monitoring and supervising tasks related to security in a plant and supporting HAZOP risk analyses with the use...

HAZOP method does not provide the completeness of risk analysis, especially indicating all causes of deviations of the process parameters which are the main risk. Particular difficulties occur when complex objects are concerned, which are decomposed into nodes for the needs of the HAZOP analysis. In the majority of cases, particular nodes are not i...

The paper presents the method of qualitative modeling of industrial process in the form of cause-and-effect graph that directly takes into account fault influence on process variables. Selected applications of that graph are briefly characterized. Its usefulness in alarm analyzes, designing of process diagnostics and HAZOP safety analyses is descri...

This paper principally focuses discussion on similarities and differences between technical and medical diagnostics. The main aim of this paper is to headline and justify those methodological achievements of the diagnostics of processes that, when implemented, may push forward development of automatized diagnostic systems intended for medical appli...

The definitions and conditions for fault isolability of single faults for various forms of the diagnostic relation are reviewed. Fault isolability and unisolability on the basis of a binary diagnostic matrix are analyzed. Definitions for conditional and unconditional isolability and unisolability on the basis of a fault information system (FIS), sy...

In this paper we present a method of diagnostic reasoning in the case of imprecise values of diagnostic signals, caused by noise, disturbances and modeling errors. Imprecise values can be handled by fuzzy logic, but fuzzy inference cannot deal with a priori probabilities of faults. Therefore we propose to use Dempster combination rule to join infor...

The paper presents a comparison of modelling methods that can be used as a tools supporting the conduction of hazard and operability study (HAZOP). The paper presents the following industrial modelling techniques: quantitative modelling using PExSim package, qualitative modelling using the GP process graph and qualitative modelling using DFM graph...

This paper presents a new idea of enhancement of the overall safety of industrial processes. The idea rely on an introduction of an additional protective-safety layer making use of advanced diagnostic systems along with the interventions of the operators and fault tolerant control systems. The structure as well as features and advantages of the ide...

This paper presents a new idea of enhancement of the overall safety of industrial processes. The idea rely on an introduction of an additional protective-safety layer making use of advanced diagnostic systems along with the interventions of the operators and fault tolerant control systems. The structure as well as features and advantages of the ide...

The operation idea of fault tolerant control systems, has been presented in the paper. Protection and security layers applied in technical diagnostics associated with safety of control system, have been discussed. The automatic control system of a steam turbine power, has been described as an example of fault tolerant control system. A steam turbin...

The problem of the on-line multiple fault isolation in diagnostics of large scale systems has been presented in this paper. Considerations about possibilities of recognition of multiple faults making use from the knowledge about signatures of single faults have been made. Distinction between simultaneous faults and series of faults has been introdu...

The survey presents a selection of the methods of the fault detection and isolation suitable to be useful for the diagnostics of the complex, large scale industrial processes. The paper focuses on these methods that have appropriately high level of potential applicability in industrial practice. The novelty of the paper relies on the discussion of...

The paper describes a number of research projects of the Faculty of Mechatronics of Warsaw University of Technology in order to illustrate the use of common mechatronics and optomechatronics approach in solving multidisciplinary technical problems. Projects on sensors development, measurement and industrial control systems, multimodal data capture...

This paper is a continuation of publication “Sequential Residual Design Method for Linear Systems” presented on SysTol'2010 conference. The method utilizes knowledge about dynamics of observed symptoms caused by occurring faults. This is an approach alternative to known methods of structural and directional residuals. Concept of designing secondary...

In this work the definitions and conditions for fault isolability in the case when model with fault influence is unknown are reviewed. Fault isolability and unisolability on the basis of binary diagnostic matrix was analysed. Definitions for conditional and unconditional isolability and unisolability on the basis of Fault Information System (FIS),...

This paper develops a new approach to double fault isolation in linear systems with the aid of directional residuals. The method of residual generation for computational as well as internal forms is applied. Isolation of double faults is based on the investigation of the coplanarity of the residual vector with the planes defined by the individual p...

In this paper, problems of the online diagnostics of multiple faults in large scale systems are presented. Possibilities of recognition of multiple faults based on the knowledge of signatures of the single faults are discussed. The distinction between simultaneous faults and the series of faults is introduced and defined. The necessary condition fo...

In this paper an analysis of the available measurement signals in external, pulsatile ventricular assist pump is carried out to evaluate their diagnostic usefulness, and to propose diagnostic system for such devices. Firstly, short description of device and used methodology is provided. Then a full set of diagnostic test is described. Next, diagnos...

The paper presents general view of the DiaSter system implementing advanced methods of modeling, diagnostics and supervisory control for industrial processes. The scope of the tasks realized in the system as well as the system software platform were characterized, in particular: the software structure, central archival and configuration databases,...

The chapter focuses on selected methods of diagnostics which have been implemented in the DiaSter system. Taking into account the specificity of industrial processes diagnostics, the robust fault detection problem is presented in the first part of the chapter. Considering the robust neural model, the passive approach based on model error modeling i...

Limitations, requirements and problems of diagnostics of complex industrial systems is discussed in this paper. Brief discussion given in Section 1 is particularly relevant to issues typical for chemical, petrochemical, power, food etc. large scale industrial installations. Section 2 of the paper lists and discusses main limitations and restriction...

Modern control systems are complex in the sense of implementing numerous functions, such as process variable processing, digital control, process monitoring and alarm indication, graphic visualization of process running, or data exchange with other systems or databases. This book conveys a description of the developed DiaSter system as well as char...

Modern control systems are complex, i.e., they implement many different functions. The basic ones include process variables processing, binary control, direct digital control, supervisory control, batch control, balance calculations, statistic indices calculation, process protection, the sequence of event processing, alarm signaling, as well as dat...

The paper presents the fault isolation method for linear systems taking into account the residual dynamics. The method is based on the analysis of the sequence of observed symptoms assuming the residual models. Additionally, the method of designing the secondary residuals that allows to achieve particular symptom sequence for particular fault is pr...

This paper describes an innovative concept for an advanced monitoring, control and diagnosis system for pumps. According to leading experts about 20% of the electrical energy used in industry is used for pumps and about 30% of this energy could be saved if intelligent control systems would be applied. In spite of this fact, currently very often no...

W referacie przedstawiono analizę i ocenę potencjału aplikacyjnego wybranych sieci przemysłowych w zastosowaniach do automatyzacji budynków. Przeanalizowano dziewięć sieci dominujących w automatyzacji przemysłowych procesów ciągłych i dyskretnych. Scharakteryzowano referencyjny zbiór cech sieci przemysłowych istotnych z punktu widzenia wykorzystani...

The DiaSter software platform is a set of programs working together to realize functionality related to process modeling, variables processing, fault detection and diagnosis, advanced control, and decision support. This chapter begins with short descriptions of main applications of the DiaSter system as a convenient tool to realize multiple functio...

The paper addresses the problem of the on-line multiple fault isolation in diagnostics of large scale systems. Considerations about possibilities of the recognition of multiple faults based on the knowledge about signatures of single faults are presented. The definition of the distinction between simultaneous faults and the series of faults is intr...

This paper addresses the problem of on-line multiple fault isolation in the large scale systems. A novel, practical and easy for implementation algorithm for reasoning about multiple faults is presented. The algorithm distinguishes itself by the significant reduction of the computational power needed for reasoning about multiple faults. An example...

The paper presents the application of AMandD system for the purpose of coke sedimentation process in the hydrocraking installation. First short description of the installation is given. Then, the summary of applied methods for monitoring of slow changes in the process are given. Next, the structure of the AMandD system is summarized. At the end, th...

The aims and tasks of on-line diagnostics of industrial processes have been discussed. Differences between classic alarm systems and diagnostics systems have been shown. Applicable detection methods as well as practical problems of diagnostics of the complex technological installations have been characterized. The diagnostic system AM&D and its pil...

A New Approach to Multiple Fault Diagnosis: A Combination of Diagnostic Matrices, Graphs, Algebraic and Rule-Based Models. The Case of Two-Layer Models The diagnosis of multiple faults is significantly more difficult than singular fault diagnosis. However, in realistic industrial systems the possibility of simultaneous occurrence of multiple faults...

The paper presents structure and functional properties of the Advanced Monitoring and Diagnostic System AMandD dedicated for applications in large scale industrial processes. Algorithms applied for modeling of processes as well as fault detection and isolation algorithms have been briefly described in the paper. Also a short description of implemen...

In the paper the problem of decomposition of the diagnostic system has been described. Principles of diagnostics in the decentralised hierarchic structure with the application of fuzzy logic have been given. The features and advantages of diagnostics of industrial processes in decentralised structures have been discussed. An industrial example of d...

This chapter presents structure and functional properties of the Advanced Monitoring and Diagnostic System "AMandD" dedicated for large-scale industrial processes. The system arose within the framework of research project "CHEM" of 5th European Framework Program. Applied in the system up-to-date algorithms of modeling methods and fault detection an...

W instalacjach technologicznych w przemysłach: energetycznym, chemicznym, hutniczym, spożywczym i wielu innych, pomimo stosowania elementów o wysokiej niezawodności, występują uszkodzenia zarówno komponentów instalacji technologicznych jak i urządzeń pomiarowych i wykonawczych. Wywołują one często znaczne i długotrwałe zakłócenia przebiegu procesu...

In the paper the influence of the dynamics of the symptoms genesis on the correctness of generated diagnoses was shown. An approach of allowing for those dynamics to be taken into account in the algorithms of parallel and serial diagnostic reasoning was given. Finally, the algorithm of proper reasoning when the information about symptoms times is o...

Symbiosis and equilibrium of methodology, technical facilities, and economy factors is necessary for development and application of diagnostics for technical systems. Comprehensive survey of diagnostics methods applicable for diagnostics of industrial processes was given in the paper. Principals of fault detection and isolation were presented. Proc...

In the paper a set of practical problems dealing with the diagnostics of the industrial processes have been presented. The most common are the problems of achievement of sufficiently high rate of fault distinguishability, problems related with the uncertainties in the diagnostic reasoning, necessity of taking into account the diagnosed system compl...

The paper discusses the problems of fault distinguishability in case of a multiple-valued evaluation of fault symptoms. Definitions of conditional and unconditional fault distinguishability are introduced to make allowance for assessment of quality of fault isolation approaches. Definitions of the sensitivity of fault distinguishability and sensiti...

Symbiosis and equilibrium of methodology, technical facilities, and economy factors is necessary for development and application of diagnostics for technical systems. Comprehensive survey of diagnostics methods applicable for diagnostics of industrial processes was given in the paper. Principals of fault detection and isolation were presented. Proc...

Knowledge about the relation betwen faults and the observed symptoms is necessary for fault isolation. Such a relation can be expressed in various forms, including binary diagnostic matrices or information systems. The paper presents the use of fuzzy logic for diagnostic reasoning. This method enables us to take into account various kinds of uncert...

In the paper the basic idea of smart diagnostic units is presented. Three different diagnostic units are defined: detectors, sensors and analysers. The idea of introduction of smart diagnostic units is coherent with the concept of decentralisation of diagnostic functions. This concept arose from the postulate of transformation of diagnostic matrix...

This paper is focused particularly on application of fuzzy logic approach for solving fault isolation problem of some classes of industrial actuators described in the benchmark actuator definition [M. Bartyś, R. Patton, M. Syfert, S. de las Heras and J. Quevedo, Introduction to the DAMADICAS actuator FDI benchmark study, Control Eng. Practice, Spec...

An overview and classification of applied modelling approaches in diagnostics of industrial processes is presented in the paper. There are characterised techniques of modelling particularly intended for fault detection and fault isolation. Particular attention was paid on the model practicability aspects. Main features of the models are pointed out...

In the paper the problem of decomposition of the diagnostic system has been described. Principles of diagnostics in the decentralised hierarchic structure with the application of fuzzy logic have been given. An example of diagnostic reasoning in the decentralised structure has been presented. The features and advantages of diagnostics of industrial...

This presentation refers to an idea of embedded diagnostics providing on-line fault detection and isolation (FDI) in mechatronic devices. The set of examples are shown including fault sensors, detectorss and analysers. The benefits of embedded diagnostics are outlined.

The requirements concerning the industrial application of fault detection and isolation seem to be quite natural taking into account process safety, end product quality and process economy factors. The pilot industrial implementations of chosen diagnostic methods will be presented and described in this chapter. Those methods are principally based o...

This chapter is an introduction to the problems of the diagnostics of processes or systems. A general methodology of system diagnostics is presented by the description of such vital elements as fault detection, isolation and identification as well as the monitoring of system states. While diagnosing the system, it is necessary to ensure adequate di...

In the paper, an overview and classification of modelling approaches used in diagnostics of industrial processes is presented. There are characterised the models used for fault detection and fault isolation. Main features of characterised models are underlined and particular attention was paid on the model practicability. Special attention was paid...

Due to the existence of various classes of diagnosed systems, different kinds of models are used in diagnostics studies which are being developed. A general description of a system that takes the effects of faults into account is usually impossible, and even if such a description exists, the dependence that characterises particular faults cannot be...

The diagnostic system is most often integrated with the automatic control system. The structures of modern computer-based automatic control systems that control industrial processes are decentralised and space-distributed (Fig. 19.1). It is advisable that diagnostic functions that constitute an integral part of control tasks and process protection...

In the last few years, there has been observed a rapid growth of interest in industrial applications of diagnostic systems. It results from potentially high economic profits which can be brought about by industrial applications, as well as from the rise of a new generation of control systems which facilitate the application of advanced software too...

In the case of industrial processes (systeIlls), diagnoses should be formulated on-line and in real time. Such a method of diagnosing is called system state monitoring (Kościelny, 2001). This chapter presents state monitoring algorithms for complex industrial installations.

The basics of fuzzy logic as well as fuzzy modelling and control are described, for example, in the monographies by Czogała and Łęski (2000), Yager and Filev (1994), Drinkov et al. (1996), Rutkowska (2002), and Piegat (2001). An interesting overview of fuzzy logic application to fault detection and isolation can be found in Frank and Marcu (2000)....

In the paper the basic idea of smart diagnostic units is presented. Three different diagnostic units are defined: detectors, sensors and analysers. The idea of introducing smart diagnostic units is coherent with the concept of decentralisation of diagnostic functions. This concept arose from the postulate of transformation of diagnostic matrix into...

W referacie przedstawiono koncepcję lokalnych jednostek diagnostycznych odgrywających rolę detektorów, sensorów i analizatorów uszkodzeń. Przedstawiono podstawowe funkcje i przykładowe struktury takich jednostek. Koncepcja jest zbieżna z ideą decentralizacji funkcji diagnostycznych. Idea wprowadzenia detektorów, sensorów i analizatorów uszkodzeń wy...

The paper concerns the problems of on-line diagnosis of industrial processes with multiple faults. The authors discussed some hypotheses of multiple faults isolation conditions. Particularly, the multiple fault isolation analysis under assumption of single faults hypothesis is discussed. The simple, practical algorithm of multiple fault isolation w...

Keywords: fuzzy logic, fuzzy applications, fault detection, parallel reasoning, serial reasoning, serial-parallel reasoning In the paper, three methods of diagnostic reasoning with application of fuzzy set theory were presented. The first method is based on parallel comparison of the vectors of ordered fuzzy diagnostic signals and fault signatur...

The paper presents application of fuzzy logic for fault detection and isolation in industrial processes, and especially for generation of residuals on the grounds of fuzzy models, residual values evaluation, description of a faults-symptoms relation, as well as diagnostic inference. Advantages of diagnostic algorithms based on fuzzy logic have been...

The paper considers application of causal graph to description of diagnosed process. Presented graph, called Graph of Process (GP), is a qualitative model of the diagnosed process with respect to faults. The graph is used for designing the model structures for fault detection and identifying of fault - symptom relations. Theoretic background of gra...

In the paper three different methods of diagnostic reasoning with application of fuzzy sets theory were briefly presented and discussed. Fuzzy logic application gives the opportunity of introducing diagnostic signal certainty degrees what is particularly important when taking into account industrial applications. The considerations were done under...

The paper presents the solutions of main problems that appear in diagnostics of large scale processes in chemical, petrochemical, pharmaceutical, power and other industry utilised in applied diagnostic software. In addition to description of reasoning rules based on fuzzy logic and taking into account the dynamics of symptoms forming the following...

In the paper three different methods of diagnostic reasoning with application of fuzzy sets theory were briefly presented and discussed. Fuzzy logic application have been given the opportunity of introducing diagnostic signal certainty degrees what is particularly important when taking into account industrial applications. The considerations were d...

Four fuzzy logic fault isolation methods suitable for embedded in smart final control elements are proposed. The methods are suited for real time diagnostics applications considering computing power limitations typical for implementations in intrinsically safe zones. The comparison of isolability features of presented algorithms is given in example...