Distributed Dynamic Modeling and Monitoring for Large-Scale Industrial Processes under Closed-Loop Control

A latent feature oriented dictionary learning method for closed-loop process monitoring

Industrial cyber-physical system (ICPS), by its powerful computing, communication, precise control and remote operation functions, has become the mainstream of modern industrial process. The observed variables of the closed-loop process in ICPS are subject to the degradation of equipment and other factors, resulting in exhibiting a stationary/nonstationary mixture feature and dynamic feature. Moreover, due to the frequent change of working conditions in the closed-loop process, the traditional open-loop process monitoring method always triggers false alarms, which will impose a negative impact on the safety and trustworthiness of ICPS. Therefore, for the closed-loop process in ICPS, a latent feature oriented dictionary learning (LFDL) method is proposed, which realizes the precise separation of latent features of raw data through three stages. First, closed-loop process variables are separated into stationary and nonstationary variables to mine the local information spatially. Then, from the temporal viewpoint, the static and dynamic features were extracted for stationary and nonstationary variables on the basis of the slow feature analysis method and cointegration analysis for local monitoring. Finally, the global monitoring results are obtained by utilizing the dictionary learning method to fuse respectively the local monitoring results of the static and dynamic features. Since the proposed method has taken the feature of the close-loop process from temporal and spatial viewpoints simultaneously, it can distinguish the normal change of operating conditions and actual faults accurately. Extensive experiments including the three-phase flow, the Tennessee Eastman process and an industrial roasting process are conducted to demonstrate the feasibility and effectiveness of the proposed method.

MoniNet With Concurrent Analytics of Temporal and Spatial Information for Fault Detection in Industrial Processes

Modern industrial plants generally consist of multiple manufacturing units, and the local correlation within each unit can be used to effectively alleviate the effect of spurious correlation and meticulously reflect the operation status of the process system. Therefore, the local correlation, which is called spatial information here, should also be taken into consideration when developing the monitoring model. In this study, a cascaded monitoring network (MoniNet) method is proposed to develop the monitoring model with concurrent analytics of temporal and spatial information. By implementing convolutional operation to each variable, the temporal information that reveals dynamic correlation of process data and spatial information that reflects local characteristics within individual operation unit can be extracted simultaneously. For each convolutional feature, a submodel is developed and then all the submodels are integrated to generate a final monitoring model. Based on the developed model, the operation status of the newly collected sample can be identified by comparing the calculated statistics with their corresponding control limits. Similar to the convolutional neural network (CNN), the MoniNet can also expand its receptive field and capture deeper information by adding more convolutional layers. Besides, the filter selection and submodel development in MoniNet can be replaced to generalize the proposed network to many existing monitoring strategies. The performance of the proposed method is validated using two real industrial processes. The illustration results show that the proposed method can effectively detect process anomalies by concurrent analytics of temporal and spatial information.