Industrial Controls Data Analytics Use Cases
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INDUSTRIAL CONTROLS DATA
ANALYTICSUSE CASES
Openlab Workshop on Data Analytics16th of November 2012
Axel Voitier – CERN EN-ICE
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Outline Industrial Control Systems at CERN
Data Sources for Analysis
Possible Use of Data Analytics:Online MonitoringFault DiagnosisEngineering Design
Where to go with our tons of data?
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Typical Industrial Control System
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Technologies Supervision layer
Siemens WinCC Open ArchitectureNational Instrument LabView
Control layerProgrammable Logic ControllersFront End ComputersVME modules, PXI controllers, etc.
Field layerSensors, devices
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Some examples Accelerators
CryogenicsVacuumMachine Protection
ExperimentsDetector ControlDetector SafetyGas
Technical InfrastructureCooling and VentilationElectricity
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Particularities of Control Systems They are stables most of the time.
Relatively few incidents to learn from.
But a single system failure can lead to a complete stop of the accelerator(s).Beam dump!Unavailability time (repair +
recovering).=> High global cost.
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Data sources for analysis Online values
Single value, instantaneous.
ArchivesLHC Logging + PVSS archives.+100 Tbytes, extensible.Data and alarms.
Log filesAlmost never used.
Configuration data16th of November 2012
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Use case 1: Online MonitoringDetect issues and inform operators before they affect the process under control.
Possible applications:Control systems health.Electrical power quality of service.Looking for heat in superconducting
magnets.Oscillation of cryogenic valves.Discharge of superconducting magnets
heaters.16th of November 2012
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Inputs/Outputs Inputs
Operating system information.Network load.PLCs status information.Process measurements.Layout database.Log messages.
Outputs Alerts, sent to our stand by service by SMS. Periodic summary reports.
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Type of analysis Analysis Processes
Thresholds learning.Correlations.Classifications.Formalisation of temporal relations (eg. Markov chain,
Wavelet, FFT).Pattern recognitions.
Time span:Learning over relatively long periods.Detection periods: “immediate”, 1 week, 1 month, 1
year.
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Example 1: Hard drive failure
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Example 2: Memory disturbance
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Example 3: Incipient fault on electrical network
Mirrasoul et Al., “Real-time automated distribution event detection and notification for grid control”, ABB Review 3/2009, p.38-44
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Current developments Exploring machine learning techniques
for control systems health monitoring.
Adrian Vlad LEP – CERN EN-ICE
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Use case 2: Fault DiagnosisHelping operators to find the root event in an avalanche of alarms.
Possible applications:Analysis of electrical power cuts.Cryogenic system breakdowns.
Complex system Break down Threshold
crossing First alarm Interlock Shutdown New alarms
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Inputs/Outputs Inputs
Hundreds of Analog/Digital Inputs/Outputs.
Event list.Alarm list.
OutputsIncident report for the operator.An identified/classified result.
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Type of analysis Analysis processes
Pattern classification.Model based methods (process simulation).Knowledge based methods (interlocks are
known).
Time spanAn avalanche of alarm is short. But…… The root cause can happen hours/days before.
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Current developments Research on cryogenic systems
breakdown diagnostic
Nabil Bouchair – CERN EN-ICE
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Use case 3: Engineering design
Analyse historical data to draw conclusions about the behaviour of a system.
Possible applications:Electrical consumption forecast.Predictive maintenance of control
systems elements.Vibration analysis.
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Inputs/Outputs Inputs
Any kind of process data.
OutputsDetailed status reports.Previsions.
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Type of analysis Analysis processes
Multivariate interpolations.Correlations.Inferences based on knowledge or
model.Unsupervised classifications.
Time spanAs long as the system has existed and
will exist.16th of November 2012
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Where to go with our tons of data? We have a lot of data!
Very few are used though.But we have some ideas…
Currently doing preliminary studiesProspect and researches.Many techniques to explore.
Challenges aheadSuitability of state of the art techniques to our domains.Integration within our tools and environment.Hard to reuse a development, every use case seems unique.
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