Fault Detection Technology for Ultrapure Water Plant using Virtual Sensors for Pressure Control Valve and Indicators in Return Line

Abstract

Objectives This study aims to propose a technology that utilizes virtual sensors to quickly and accurately diagnose faults in valves and measurement devices that may occur in the return line of an ultrapure water plant. Methods The empirical equations were derived, and the error range was calculated using operational data collected from three pieces of equipment (pressure control valve, pressure transmitter, and flow transmitter) in the recovery system of the ultrapure water process. Based on this, a virtual sensor is established. Results and Discussion It was confirmed that the utilization of 24-hour data collected from the operation of the ultrapure water plant was enough to establish virtual sensors and could also estimate monthly data with high accuracy. In Phase 1, the fault diagnosis technology was found to estimate values more accurately and had a meaningful margin of error compared to Phase 2. Conclusion It was possible to develop a fault detection technology using the virtual sensor derived from the empirical equation. The technology showed high performance in detecting anomalies in the flow meter and pressure control valve opening but had limitations in estimating consistently pressure values. Additionally, considering that there was no issue in estimating monthly data using the equations derived using 24 hours operational data. The fault detection algorithm could be used continuously if the empirical equations are updated by collecting a day's data when operating conditions change.

Keywords

• ultrapure water process
• fault detection
• flow indicator
• pressure control valve
• pressure indicator