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研究生：	葉鳴麗 Yeh, Ming-Li
論文名稱：	以自動機為基礎之批次製程異常狀態管理方法 Automata Based Methods for Abnormal Situation Management in Batch Processes
指導教授：	張珏庭 Chang, Chuei-Tin
學位類別：	博士 Doctor
系所名稱：	工學院 - 化學工程學系 Department of Chemical Engineering
論文出版年：	2013
畢業學年度：	101
語文別：	英文
論文頁數：	187
中文關鍵詞：	自動機、批次製程、失誤診斷、診斷器、監督器、危機應變
外文關鍵詞：	Automaton, Batch Process, Failure diagnosis, Diagnoser, Supervisor, Emergency response
相關次數：	點閱：123 下載：1
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異常狀態管理包含了工廠在可接受的正常區域範圍中操作條件重大偏離之即時辨識與減輕。由於沒有效率的異常狀態管理會造成化學工廠中重大的安全與經濟衝擊，因此本論文針對發展異常狀態管理方法的兩項重要議題進行探討：(1) 批次化學品製程的線上失誤診斷分析與(2)自動化合成批次操作步驟。
為了達成這兩項研究議題，我們首先發展系統化的自動機建模方法來描述批次製程中硬體設備(元件)的狀態轉移行為及其失誤傳播機制。根據批次製程的階層結構，將所有的元件進行結合，可得到批次化學品製程的系統模型。此建模方法已成功地利用多個案例研究完成測試。
為了決定定性和定量的診斷性能指標，我們利用上述所建立的製程系統的自動機模型，來自動建構能夠對製程系統進行線上危害鑑識的診斷器。另外，本研究還進一步開發兩項可提高診斷性能的策略來提高失誤診斷的解析度以精確地分辨失誤來源：(1)設置未裝設於順序功能流程圖中的額外感測器與(2)加入未設定於順序功能流程圖中的額外操作步驟。
有關自動化合成批次操作步驟此研究議題，我們開發系統化的策略來自動合成正常與異常系統條件下的批次製程操作步驟。具體而言，我們首先發展標準型式的規格模式，接著，利用平行組合操作方法將系統模式與規格模式進行結合，以自動合成製程系統的可接受監督器。最後，為了決定可實際執行的最有效的操作步驟，可再利用額外輔助的自動機模式來修飾可接受監督器的操作目標並限制操作動作和操作步驟的數目。
我們以案例研究驗證本研究所提出策略的可行性與正確性。我們發現所提出的策略可以應用於非常複雜的案例，因此，有助於改善實際製程中的異常狀態管理。

Abnormal situation management (ASM) involves timely identification and mitigation of significant departures of the operating conditions in a plant from an acceptable normal region. Ineffective ASM may give rise to detrimental consequences with enormous financial implications. Two important research issues are addressed in this thesis, i.e., (1) online failure diagnosis in batch chemical processes and (2) automatic synthesis of batch operating procedures.
In order to achieve the research objectives in both areas, the state transition behaviors of all hardware items (components) in the given batch process and their failure mechanisms are modeled systematically with automata. The overall system model can be assembled by connecting these automata on the basis of a generic hierarchical structure. This modeling approach has been successfully tested with a large number of examples.
A "diagnoser" can be produced on the basis of the aforementioned system model for the purpose of evaluating diagnostic uncertainty indices. Guided by these indices, two performance enhancement measures can be effectively implemented: (1) installing auxiliary devices which are not included in the piping and instrumentation diagram (P&ID) and (2) executing diagnostic tests which are not specified in the sequential function chart (SFC).
For the second research issue, a systematic strategy is provided in this thesis for synthesizing operating procedures under normal or abnormal system conditions. By following the proposed modeling rules, a set of automata can be constructed in advance to represent the control specifications. An admissible supervisor can then be produced by applying the parallel composition operation with the system and specification models. For the purpose of identifying the most efficient procedures, this admissible supervisor is integrated further with the auxiliary automata for setting the operation target(s) and imposing upper limits on the total numbers of actuator actions.
Extensive case studies are presented in this thesis to demonstrate the feasibility and correctness of all proposed methods. It can be observed that the proposed strategies are effective even for very complex cases and, thus, should be useful for improving ASM in realistic processes.

摘要‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥i
Abstract‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥iii
致謝‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥v
Contents‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥vi
List of Tables‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ix
List of Figures‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥xi

Chapter
Introduction                                               1
1	Background‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥1
2	Literature Review‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥2
3	Research Objectives‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥6
4	Thesis Organization‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥6
Modeling the Batch Processes with Automata              7
1	Automata and Discrete-Event Systems‥‥‥‥‥‥‥‥‥7
2	Hierarchical Structure of Batch Processes‥‥‥‥‥8
3	Model-Building Procedure‥‥‥‥‥‥‥‥‥‥‥‥‥‥11
3.1	Developing Component Models‥‥‥‥‥‥‥‥‥‥‥‥‥11
3.2	Assembling System Model‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥19
3.3	Parallel Composition‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥23
4.1	Additional Examples‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥25
4.1	Example II‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥26
4.2	Example III‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥33
4.3	Example IV‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥39
4.4	Example V‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥41
4.5	Example VI‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥45
Assessment of Online Diagnosis Schemes for Multi-Failure Scenarios                                                53
1	Construction of Diagnosers‥‥‥‥‥‥‥‥‥‥‥‥‥53
2	Generation of Live Automata‥‥‥‥‥‥‥‥‥‥‥‥‥55
3	Evaluation of Diagnostic Performance‥‥‥‥‥‥‥‥59
3.1	Identifiable Features in a Diagnoser‥‥‥‥‥‥‥‥59
3.2	Qualitative Measure‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥61
3.3	Quantitative Measure‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥62
4	A Simple Example‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥63
5	Revamp Options for Performance Enhancement‥‥‥‥65
5.1	Additional Sensors‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥65
5.2	Extra Operation Steps‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥66
6	Case Studies‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥66
6.1	Case 3.1‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥67
6.2	Case 3.2‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥72
7	Summary‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥76
Systematic Synthesis of Operating Procedures under Normal Process Conditions                                77
1	Systematic Synthesis Procedure‥‥‥‥‥‥‥‥‥‥‥77
1.1	Components‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥78
1.2	Control Specifications‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥78
1.3	Supervisor Generation‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥81
1.4	Procedure Synthesis‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥90
2	Case Studies‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥92
2.1	Case 4.1‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥92
2.2	Case 4.2‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥93
3	Summary ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥108
Systematic Generation of Emergency Response Procedures109
1	Procedure Synthesis Strategy‥‥‥‥‥‥‥‥‥‥‥‥109
1.1	Control Specifications‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥109
1.2	Admissible Supervisors‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥111
1.3	Implementable Supervisors‥‥‥‥‥‥‥‥‥‥‥‥‥115
2	An additional Example‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥116
2.1	Process Configurations‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥120
2.2	Component Models‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥125
2.3	Control Specifications‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥131
2.4	Scenario 1‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥133
2.5	Scenario 2‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥148
3	Summary‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥153
Conclusions and Future Works                          154
1	Conclusions ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥154
2	Future Works ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥154
Bibliography                                             156
Appendix A                                               166
Appendix B                                               177
Autobiography                                            186
Publications                                             187
                                    

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