Global–Local Structure Analysis Model and Its Application for Fault Detection and Identification

A Review on Data-Driven Process Monitoring Methods: Characterization and Mining of Industrial Data

Safe and stable operation plays an important role in the chemical industry. Fault detection and diagnosis (FDD) make it possible to identify abnormal process deviations early and assist operators in taking proper action against fault propagation. After decades of development, data-driven process monitoring technologies have gradually attracted attention from process industries. Although many promising FDD methods have been proposed from both academia and industry, challenges remain due to the complex characteristics of industrial data. In this work, classical and recent research on data-driven process monitoring methods is reviewed from the perspective of characterizing and mining industrial data. The implementation framework of data-driven process monitoring methods is first introduced. State of art of process monitoring methods corresponding to common industrial data characteristics are then reviewed. Finally, the challenges and possible solutions for actual industrial applications are discussed.

Fault Detection Method Based on Global-Local Marginal Discriminant Preserving Projection for Chemical Process

Feature extraction plays a key role in fault detection methods. Most existing methods focus on comprehensive and accurate feature extraction of normal operation data to achieve better detection performance. However, discriminative features based on historical fault data are usually ignored. Aiming at this point, a global-local marginal discriminant preserving projection (GLMDPP) method is proposed for feature extraction. Considering its comprehensive consideration of global and local features, global-local preserving projection (GLPP) is used to extract the inherent feature of the data. Then, multiple marginal fisher analysis (MMFA) is introduced to extract the discriminative feature, which can better separate normal data from fault data. On the basis of fisher framework, GLPP and MMFA are integrated to extract inherent and discriminative features of the data simultaneously. Furthermore, fault detection methods based on GLMDPP are constructed and applied to the Tennessee Eastman (TE) process. Compared with the PCA and GLPP method, the effectiveness of the proposed method in fault detection is validated with the result of TE process.

Fault Monitoring of Chemical Process Based on Sliding Window Wavelet DenoisingGLPP

In industrial process fault monitoring, it is very important to collect accurate data, but in the actual process, there are often various noises that are difficult to eliminate in the collected data due to sensor accuracy, measurement errors, or human factors. Existing statistical process monitoring methods often ignore the problem of data noise. To solve this problem, a sliding window wavelet denoising-global local preserving projections (SWWD-GLPP) process monitoring method is proposed. In the offline stage, the wavelet denoising method is used to denoise the offline data, and then, the GLPP method is used for offline modeling, and then, the control limit is obtained by the kernel density estimation method. In the online phase, the sliding window wavelet denoising method is used to denoise the online data in real time. Then, use the model of the GLPP method to find the statistics, compare them with the control limit, judge the fault situation, and finally, use the contribution graph method to determine the variable that caused the fault, so as to diagnose the fault. This article uses a numerical case to illustrate the effectiveness of the algorithm, using the Tennessee Eastman (TE) process to compare the traditional principal component analysis (PCA) and GLPP methods to further prove the effectiveness and superiority of the method.

Temporal-Spatial Neighborhood Enhanced Sparse Autoencoder for Nonlinear Dynamic Process Monitoring

Data-based process monitoring methods have received tremendous attention in recent years, and modern industrial process data often exhibit dynamic and nonlinear characteristics. Traditional autoencoders, such as stacked denoising autoencoders (SDAEs), have excellent nonlinear feature extraction capabilities, but they ignore the dynamic correlation between sample data. Feature extraction based on manifold learning using spatial or temporal neighbors has been widely used in dynamic process monitoring in recent years, but most of them use linear features and do not take into account the complex nonlinearities of industrial processes. Therefore, a fault detection scheme based on temporal-spatial neighborhood enhanced sparse autoencoder is proposed in this paper. Firstly, it selects the temporal neighborhood and spatial neighborhood of the sample at the current time within the time window with a certain length, the spatial similarity and time serial correlation are used for weighted reconstruction, and the reconstruction combines the current sample as the input of the sparse stack autoencoder (SSAE) to extract the correlation features between the current sample and the neighborhood information. Two statistics are constructed for fault detection. Considering that both types of neighborhood information contain spatial-temporal structural features, Bayesian fusion strategy is used to integrate the two parts of the detection results. Finally, the superiority of the method in this paper is illustrated by a numerical example and the Tennessee Eastman process.

A modified neighborhood preserving embedding-based incipient fault detection with applications to small-scale cyber-physical systems

Industrial cyber-physical systems (ICPSs) are backbones of the Industrial 4.0 where control, physical entities, and monitoring are intensively interacted. Aiming to improve safety of a small-scale ICPS whose physical entity is an electrical drive system, this paper will develop a new detection strategy for incipient faults in neighborhood preserving embedding (NPE) framework that can provide stable solutions. The proposed modified NPE can not only extract local information effectively on data manifold of the ICPS but also solve the singularity problem caused by generalized eigenvalue decomposition skills. Additional advantages of this design for ICPSs include the enhanced fault detectability, inherent scalability, and accelerated computation efficiency. The proposed method is firstly evaluated by mathematical deviations and then is evaluated by its application to a small-scale ICPS. Three sets of experimental results show the efficacy of the proposed method in dealing with online detection of incipient faults in the ICPS.

Neighborhood preserving neural network for fault detection

A novel statistical feature extraction method, called the neighborhood preserving neural network (NPNN), is proposed in this paper. NPNN can be viewed as a nonlinear data-driven fault detection technique through preserving the local geometrical structure of normal process data. The "local geometrical structure " means that each sample can be constructed as a linear combination of its neighbors. NPNN is characterized by adaptively training a nonlinear neural network which takes the local geometrical structure of the data into consideration. Moreover, in order to extract uncorrelated and faithful features, NPNN adopts orthogonal constraints in the objective function. Through backpropagation and eigen decomposition (ED) technique, NPNN is optimized to extract low-dimensional features from original high-dimensional process data. After nonlinear feature extraction, Hotelling T² statistic and the squared prediction error (SPE) statistic are utilized for the fault detection tasks. The advantages of the proposed NPNN method are demonstrated by both theoretical analysis and case studies on the Tennessee Eastman (TE) benchmark process. Extensive experimental results show the superiority of NPNN in terms of missed detection rate (MDR) and false alarm rate (FAR). The source code of NPNN can be found in https://github.com/htzhaoecust/npnn.

Statistical process monitoring based on orthogonal multi-manifold projections and a novel variable contribution analysis

Multivariate statistical methods have been widely applied to develop data-based process monitoring models. Recently, a multi-manifold projections (MMP) algorithm was proposed for modeling and monitoring chemical industrial processes, the MMP is an effective tool for preserving the global and local geometric structure of the original data space in the reduced feature subspace, but it does not provide orthogonal basis functions for data reconstruction. Recognition of this issue, an improved version of MMP algorithm named orthogonal MMP (OMMP) is formulated. Based on the OMMP model, a further processing step and a different monitoring index are proposed to model and monitor the variation in the residual subspace. Additionally, a novel variable contribution analysis is presented for fault diagnosis by integrating the nearest in-control neighbor calculation and reconstruction-based contribution analysis. The validity and superiority of the proposed fault detection and diagnosis strategy are then validated through case studies on the Tennessee Eastman benchmark process.