Fault Detection and Monitoring of Length Loop Control System in Pickling Process

Modern manufacturing facilities are large scale, highly complex, and operate with large number of variables under closed loop control. Early and accurate fault detection and diagnosis for these plants can minimise down time, increase the safety of plant operations, and reduce manufacturing costs. Fault detection and isolation is more complex particularly in the case of the faulty analog control systems. Analog control system is not equipped with monitoring function where the process parameters are continually visualised. We consider in this paper an approach to fault detection and isolation in the pickling process in cold rolling. The fault appeared on one of the power unit driving a rotary machine, this machine can not track a reference speed given by another machine. Using a computerised data acquisition system, the main machine parameters have been monitored. The fault has been detected and isolated on basis of analysis of monitored data. Normal and faulty situation have been obtained by an artificial neural network (ANN) model which is implemented to simulate the normal and faulty status of rotary machine