Expert system for fault diagnosis in process control valves using fuzzy-logic

The models of asset maintenance of a process plant basically are classified in corrective maintenance, preventive, predictive and proactive (online). The corrective maintenance is the elementary and most obvious way of the maintenance models. The preventive maintenance consists in a fault prevention work, based on statistical studies that can lead to low efficiency or even an unexpected shutdown of the plant. Predictive maintenance aims to prevent equipment or systems failures through monitoring and tracking of parameters, allowing continuous operation as long as possible. The proactive maintenance usually includes predictive maintenance, emphasizing the root cause analysis of the failure. The maintenance predictive/proactive planning frequently uses software that integrates data from different systems, which facilitates a quick and effective decision- making. In nuclear plants this model has an important role regarding the reliability of equipment and systems. The main focus of this work is to study the development of a model of non-intrusive monitoring and diagnosis applied to process control valves using artificial intelligence by fuzzy logic technique, contributing in the development of predictive methodologies identifying faults in incipient state. The control valve analyzed belongs to a steam plant which simulates the secondary circuit of a PWR nuclear reactor - Pressurized Water Reactor. This study makes use of MATLAB language through the fuzzy logic toolbox which uses the method of inference Mamdani, acting by fuzzy conjunction, through Triangular Norms (t-norm) and Triangular Conorms (t-conorm). As input variables are used air pressure and displacement of the valve stem. Input data coming into the fuzzy system by graph of the automation system Delta V ® available in the plant, which receives a signal of electric current from an 'intelligent' positioned installed on the valve. The output variable is the 'status' of the valve. Through a rule base established by experts, it becomes possible to investigate failures establishing the operational status of the valve which constitutes the output of the expert system. (author)