Data-driven Soft Sensors in the Process Industry

In the last two decades Soft Sensors established themselves as a valuable alternative to the traditional means for the acquisition of critical process variables, process monitoring and other tasks which are related to process control. This paper discusses characteristics of the process industry data which are critical for the development of data-driven Soft Sensors. These characteristics are common to a large number of process industry fields, like the chemical industry, bioprocess industry, steel industry, etc. The focus of this work is put on the data-driven Soft Sensors because of their growing popularity, already demonstrated usefulness and huge, though yet not completely realised, potential. A comprehensive selection of case studies covering the three most important Soft Sensor application fields, a general introduction to the most popular Soft Sensor modelling techniques as well as a discussion of some open issues in the Soft Sensor development and maintenance and their possible solutions are the main contributions of this work

A self-validating control system based approach to plant fault detection and diagnosis

An approach is proposed in which fault detection and diagnosis (FDD) tasks are distributed to separate FDD modules associated with each control system located throughout a plant. Intended specifically for those control systems that inherently eliminate steady state error, it is modular, steady state based, requires very little process specific information and therefore should be attractive to control systems implementers who seek economies of scale. The approach is applicable to virtually all types of process plant, whether they are open loop stable or not, have a type or class number of zero or not and so on. Based on qualitative reasoning, the approach is founded on the application of control systems theory to single and cascade control systems with integral action. This results in the derivation of cause-effect knowledge and fault isolation procedures that take into account factors like interactions between control systems, and the availability of non-control-loop-based sensors

Data-based fault detection in chemical processes: Managing records with operator intervention and uncertain labels

Developing data-driven fault detection systems for chemical plants requires managing uncertain data labels and dynamic attributes due to operator-process interactions. Mislabeled data is a known problem in computer science that has received scarce attention from the process systems community. This work introduces and examines the effects of operator actions in records and labels, and the consequences in the development of detection models. Using a state space model, this work proposes an iterative relabeling scheme for retraining classifiers that continuously refines dynamic attributes and labels. Three case studies are presented: a reactor as a motivating example, flooding in a simulated de-Butanizer column, as a complex case, and foaming in an absorber as an industrial challenge. For the first case, detection accuracy is shown to increase by 14% while operating costs are reduced by 20%. Moreover, regarding the de-Butanizer column, the performance of the proposed strategy is shown to be 10% higher than the filtering strategy. Promising results are finally reported in regard of efficient strategies to deal with the presented problemPeer ReviewedPostprint (author's final draft

A probabilistic model for information and sensor validation

This paper develops a new theory and model for information and sensor validation. The model represents relationships between variables using Bayesian networks and utilizes probabilistic propagation to estimate the expected values of variables. If the estimated value of a variable differs from the actual value, an apparent fault is detected. The fault is only apparent since it may be that the estimated value is itself based on faulty data. The theory extends our understanding of when it is possible to isolate real faults from potential faults and supports the development of an algorithm that is capable of isolating real faults without deferring the problem to the use of expert provided domain-specific rules. To enable practical adoption for real-time processes, an any time version of the algorithm is developed, that, unlike most other algorithms, is capable of returning improving assessments of the validity of the sensors as it accumulates more evidence with time. The developed model is tested by applying it to the validation of temperature sensors during the start-up phase of a gas turbine when conditions are not stable; a problem that is known to be challenging. The paper concludes with a discussion of the practical applicability and scalability of the model

Towards distributed diagnosis of the Tennessee Eastman process benchmark

A distributed hybrid strategy is outlined for the isolation of faults and disturbances in the Tennessee Eastman process, which would build on existing structures for distributed control systems, so should be easy to implement, be cheap and be widely applicable. The main emphasis in the paper is on one component of the strategy, a steady-state-based approach. Results obtained by applying this approach are presented and knowledge limitations are discussed. In particular a way in which a knowledge-base might evolve to improve isolation capabilities is suggested and the role of the operator is briefly discussed