Feedback-controlled CSTR Process for Fault Simulation

Three-state closed-loop CSTR dynamic model with simulation of incipient faults

This is a Simulink model of a CSTR under closed-loop control, where the process is represented by 3 ODEs (ordinary differential equations) which are mass and energy balances around the system.

The CSTR (continuous stirred-tank reactor) carries out a hypothetical first-order exothermic reaction, where the tank temperature (T) is maintained using a cooling jacket. Process conditions are being perturbed around the nominal operating point by random disturbances on 3 input variables.

Faults can be simulated for process monitoring research purposes. Incipient faults include sensor bias ramp changes and input disturbance ramp changes. Multiplicative faults include catalyst deactivation and heat transfer fouling by exponential decay. Any combination of these faults may also be simulated together. When no faults are simulated, one can gain process understanding of the system dynamics under normal operation.

References:

[1] Pilario, K.E.S. and Cao, Y. "Canonical Variate Dissimilarity Analysis for Process Incipient Fault Detection," IEEE Transactions on Industrial Informatics, 2018. DOI: 10.1109/TII.2018.2810822

[2] Pilario, K.E.S., Cao, Y., and Shafiee, M. "Mixed Kernel Canonical Variate Dissimilarity Analysis for Incipient Fault Monitoring in Nonlinear Dynamic Processes". Comput. Chem. Eng. 123, pp. 143-154, 2019. DOI: 10.1016/j.compchemeng.2018.12.027