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The detection and diagnosis of faults in technical systems are of great practical significance and paramount importance for the safe operation of the plant. The early detection of fault can help avoid system shutdown, breakdown and even catastrophe involving human fatalities and material damage. Since the operator cannot monitor all variables simultaneously, an automated approach is needed for the real time monitoring and diagnosis of the system. This paper presents the design and development of artificial neural network based model for the fault detection of Pneumatic valve in cooler water spray system in cement industry. The network is developed to detect a totally nineteen faults. The training and testing data required to develop the neural network model were generated at different operating conditions by operating the pneumatic valve and by creating various faults in real time in a laboratory experimental model. The performance of the developed back propagation is found to be satisfactory for the real time fault diagnosis.

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