Wind turbine condition monitoring strategy through multiway PCA and multivariate inference

This article states a condition monitoring strategy for wind turbines using a statistical data-driven modeling approach by means of supervisory control and data acquisition (SCADA) data. Initially, a baseline data-based model is obtained from the healthy wind turbine by means of multiway principal component analysis (MPCA). Then, when the wind turbine is monitorized, new data is acquired and projected into the baseline MPCA model space. The acquired SCADA data are treated as a random process given the random nature of the turbulent wind. The objective is to decide if the multivariate distribution that is obtained from the wind turbine to be analyzed (healthy or not) is related to the baseline one. To achieve this goal, a test for the equality of population means is performed. Finally, the results of the test can determine that the hypothesis is rejected (and the wind turbine is faulty) or that there is no evidence to suggest that the two means are different, so the wind turbine can be considered as healthy. The methodology is evaluated on a wind turbine fault detection benchmark that uses a 5 MW high-fidelity wind turbine model and a set of eight realistic fault scenarios. It is noteworthy that the results, for the presented methodology, show that for a wide range of significance, a in [1%, 13%], the percentage of correct decisions is kept at 100%; thus it is a promising tool for real-time wind turbine condition monitoring.Peer ReviewedPostprint (published version

Data-Driven Fault Detection and Reasoning for Industrial Monitoring

This open access book assesses the potential of data-driven methods in industrial process monitoring engineering. The process modeling, fault detection, classification, isolation, and reasoning are studied in detail. These methods can be used to improve the safety and reliability of industrial processes. Fault diagnosis, including fault detection and reasoning, has attracted engineers and scientists from various fields such as control, machinery, mathematics, and automation engineering. Combining the diagnosis algorithms and application cases, this book establishes a basic framework for this topic and implements various statistical analysis methods for process monitoring. This book is intended for senior undergraduate and graduate students who are interested in fault diagnosis technology, researchers investigating automation and industrial security, professional practitioners and engineers working on engineering modeling and data processing applications. This is an open access book

Statistical process monitoring of a multiphase flow facility

Industrial needs are evolving fast towards more flexible manufacture schemes. As a consequence, it is often required to adapt the plant production to the demand, which can be volatile depending on the application. This is why it is important to develop tools that can monitor the condition of the process working under varying operational conditions. Canonical Variate Analysis (CVA) is a multivariate data driven methodology which has been demonstrated to be superior to other methods, particularly under dynamically changing operational conditions. These comparative studies normally use computer simulated data in benchmark case studies such as the Tennessee Eastman Process Plant (Ricker, N.L. Tennessee Eastman Challenge Archive, Available at 〈http://depts.washington.edu/control/LARRY/TE/download.html〉 Accessed 21.03.2014). The aim of this work is to provide a benchmark case to demonstrate the ability of different monitoring techniques to detect and diagnose artificially seeded faults in an industrial scale multiphase flow experimental rig. The changing operational conditions, the size and complexity of the test rig make this case study an ideal candidate for a benchmark case that provides a test bed for the evaluation of novel multivariate process monitoring techniques performance using real experimental data. In this paper, the capabilities of CVA to detect and diagnose faults in a real system working under changing operating conditions are assessed and compared with other methodologies. The results obtained demonstrate that CVA can be effectively applied for the detection and diagnosis of faults in real complex systems, and reinforce the idea that the performance of CVA is superior to other algorithms

Control theoretically explainable application of autoencoder methods to fault detection in nonlinear dynamic systems

This paper is dedicated to control theoretically explainable application of autoencoders to optimal fault detection in nonlinear dynamic systems. Autoencoder-based learning is a standard method of machine learning technique and widely applied for fault (anomaly) detection and classification. In the context of representation learning, the so-called latent (hidden) variable plays an important role towards an optimal fault detection. In ideal case, the latent variable should be a minimal sufficient statistic. The existing autoencoder-based fault detection schemes are mainly application-oriented, and few efforts have been devoted to optimal autoencoder-based fault detection and explainable applications. The main objective of our work is to establish a framework for learning autoencoder-based optimal fault detection in nonlinear dynamic systems. To this aim, a process model form for dynamic systems is firstly introduced with the aid of control and system theory, which also leads to a clear system interpretation of the latent variable. The major efforts are devoted to the development of a control theoretical solution to the optimal fault detection problem, in which an analog concept to minimal sufficient statistic, the so-called lossless information compression, is introduced for dynamic systems and fault detection specifications. In particular, the existence conditions for such a latent variable are derived, based on which a loss function and further a learning algorithm are developed. This learning algorithm enables optimally training of autoencoders to achieve an optimal fault detection in nonlinear dynamic systems. A case study on three-tank system is given at the end of this paper to illustrate the capability of the proposed autoencoder-based fault detection and to explain the essential role of the latent variable in the proposed fault detection system

Data-Driven Fault Detection and Reasoning for Industrial Monitoring

This open access book assesses the potential of data-driven methods in industrial process monitoring engineering. The process modeling, fault detection, classification, isolation, and reasoning are studied in detail. These methods can be used to improve the safety and reliability of industrial processes. Fault diagnosis, including fault detection and reasoning, has attracted engineers and scientists from various fields such as control, machinery, mathematics, and automation engineering. Combining the diagnosis algorithms and application cases, this book establishes a basic framework for this topic and implements various statistical analysis methods for process monitoring. This book is intended for senior undergraduate and graduate students who are interested in fault diagnosis technology, researchers investigating automation and industrial security, professional practitioners and engineers working on engineering modeling and data processing applications. This is an open access book

Latent variable modeling approaches to assist the implementation of quality-by-design paradigms in pharmaceutical development and manufacturing

With the introduction of the Quality-by-Design (QbD) initiative, the American Food and Drug Administration and the other pharmaceutical regulatory Agencies aimed to change the traditional approaches to pharmaceutical development and manufacturing. Pharmaceutical companies have been encouraged to use systematic and science-based tools for the design and control of their processes, in order to demonstrate a full understanding of the driving forces acting on them. From an engineering perspective, this initiative can be seen as the need to apply modeling tools in pharmaceutical development and manufacturing activities. The aim of this Dissertation is to show how statistical modeling, and in particular latent variable models (LVMs), can be used to assist the practical implementation of QbD paradigms to streamline and accelerate product and process design activities in pharmaceutical industries, and to provide a better understanding and control of pharmaceutical manufacturing processes. Three main research areas are explored, wherein LVMs can be applied to support the practical implementation of the QbD paradigms: process understanding, product and process design, and process monitoring and control. General methodologies are proposed to guide the use of LVMs in different applications, and their effectiveness is demonstrated by applying them to industrial, laboratory and simulated case studies. With respect to process understanding, a general methodology for the use of LVMs is proposed to aid the development of continuous manufacturing systems. The methodology is tested on an industrial process for the continuous manufacturing of tablets. It is shown how LVMs can model jointly data referred to different raw materials and different units in the production line, allowing to understand which are the most important driving forces in each unit and which are the most critical units in the line. Results demonstrate how raw materials and process parameters impact on the intermediate and final product quality, enabling to identify paths along which the process moves depending on its settings. This provides a tool to assist quality risk assessment activities and to develop the control strategy for the process. In the area of product and process design, a general framework is proposed for the use of LVM inversion to support the development of new products and processes. The objective of model inversion is to estimate the best set of inputs (e.g., raw material properties, process parameters) that ensure a desired set of outputs (e.g., product quality attributes). Since the inversion of an LVM may have infinite solutions, generating the so-called null space, an optimization framework allowing to assign the most suitable objectives and constraints is used to select the optimal solution. The effectiveness of the framework is demonstrated in an industrial particle engineering problem to design the raw material properties that are needed to produce granules with desired characteristics from a high-shear wet granulation process. Results show how the framework can be used to design experiments for new products design. The analogy between the null space and the Agencies’ definition of design space is also demonstrated and a strategy to estimate the uncertainties in the design and in the null space determination is provided. The proposed framework for LVM inversion is also applied to assist the design of the formulation for a new product, namely the selection of the best excipient type and amount to mix with a given active pharmaceutical ingredient (API) to obtain a blend of desired properties. The optimization framework is extended to include constraints on the material selection, the API dose or the final tablet weight. A user-friendly interface is developed to aid formulators in providing the constraints and objectives of the problem. Experiments performed industrially on the formulation designed in-silico confirm that model predictions are in good agreement with the experimental values. LVM inversion is shown to be useful also to address product transfer problems, namely the problem of transferring the manufacturing of a product from a source plant, wherein most of the experimentation has been carried out, to a target plant which may differ for size, lay-out or involved units. An experimental process for pharmaceutical nanoparticles production is used as a test bed. An LVM built on different plant data is inverted to estimate the most suitable process conditions in a target plant to produce nanoparticles of desired mean size. Experiments designed on the basis of the proposed LVM inversion procedure demonstrate that the desired nanoparticles sizes are obtained, within experimental uncertainty. Furthermore, the null space concept is validated experimentally. Finally, with respect to the process monitoring and control area, the problem of transferring monitoring models between different plants is studied. The objective is to monitor a process in a target plant where the production is being started (e.g., a production plant) by exploiting the data available from a source plant (e.g., a pilot plant). A general framework is proposed to use LVMs to solve this problem. Several scenarios are identified on the basis of the available information, of the source of data and on the type of variables to include in the model. Data from the different plants are related through subsets of variables (common variables) measured in both plants, or through plant-independent variables obtained from conservation balances (e.g., dimensionless numbers). The framework is applied to define the process monitoring model for an industrial large-scale spray-drying process, using data available from a pilot-scale process. The effectiveness of the transfer is evaluated in terms of monitoring performances in the detection of a real fault occurring in the target process. The proposed methodologies are then extended to batch systems, considering a simulated penicillin fermentation process. In both cases, results demonstrate that the transfer of knowledge from the source plant enables better monitoring performances than considering only the data available from the target plant

An Efficient Quality-Related Fault Diagnosis Method for Real-Time Multimode Industrial Process

Focusing on quality-related complex industrial process performance monitoring, a novel multimode process monitoring method is proposed in this paper. Firstly, principal component space clustering is implemented under the guidance of quality variables. Through extraction of model tags, clustering information of original training data can be acquired. Secondly, according to multimode characteristics of process data, the monitoring model integrated Gaussian mixture model with total projection to latent structures is effective after building the covariance description form. The multimode total projection to latent structures (MTPLS) model is the foundation of problem solving about quality-related monitoring for multimode processes. Then, a comprehensive statistics index is defined which is based on the posterior probability of the monitored samples belonging to each Gaussian component in the Bayesian theory. After that, a combined index is constructed for process monitoring. Finally, motivated by the application of traditional contribution plot in fault diagnosis, a gradient contribution rate is applied for analyzing the variation of variable contribution rate along samples. Our method can ensure the implementation of online fault monitoring and diagnosis for multimode processes. Performances of the whole proposed scheme are verified in a real industrial, hot strip mill process (HSMP) compared with some existing methods

Novel chemometric proposals for advanced multivariate data analysis, processing and interpretation

The present Ph.D. thesis, primarily conceived to support and reinforce the relation between academic and industrial worlds, was developed in collaboration with Shell Global Solutions (Amsterdam, The Netherlands) in the endeavour of applying and possibly extending well-established latent variable-based approaches (i.e. Principal Component Analysis - PCA - Partial Least Squares regression - PLS - or Partial Least Squares Discriminant Analysis - PLSDA) for complex problem solving not only in the fields of manufacturing troubleshooting and optimisation, but also in the wider environment of multivariate data analysis. To this end, novel efficient algorithmic solutions are proposed throughout all chapters to address very disparate tasks, from calibration transfer in spectroscopy to real-time modelling of streaming flows of data. The manuscript is divided into the following six parts, focused on various topics of interest: Part I - Preface, where an overview of this research work, its main aims and justification is given together with a brief introduction on PCA, PLS and PLSDA; Part II - On kernel-based extensions of PCA, PLS and PLSDA, where the potential of kernel techniques, possibly coupled to specific variants of the recently rediscovered pseudo-sample projection, formulated by the English statistician John C. Gower, is explored and their performance compared to that of more classical methodologies in four different applications scenarios: segmentation of Red-Green-Blue (RGB) images, discrimination of on-/off-specification batch runs, monitoring of batch processes and analysis of mixture designs of experiments; Part III - On the selection of the number of factors in PCA by permutation testing, where an extensive guideline on how to accomplish the selection of PCA components by permutation testing is provided through the comprehensive illustration of an original algorithmic procedure implemented for such a purpose; Part IV - On modelling common and distinctive sources of variability in multi-set data analysis, where several practical aspects of two-block common and distinctive component analysis (carried out by methods like Simultaneous Component Analysis - SCA - DIStinctive and COmmon Simultaneous Component Analysis - DISCO-SCA - Adapted Generalised Singular Value Decomposition - Adapted GSVD - ECO-POWER, Canonical Correlation Analysis - CCA - and 2-block Orthogonal Projections to Latent Structures - O2PLS) are discussed, a new computational strategy for determining the number of common factors underlying two data matrices sharing the same row- or column-dimension is described, and two innovative approaches for calibration transfer between near-infrared spectrometers are presented; Part V - On the on-the-fly processing and modelling of continuous high-dimensional data streams, where a novel software system for rational handling of multi-channel measurements recorded in real time, the On-The-Fly Processing (OTFP) tool, is designed; Part VI - Epilogue, where final conclusions are drawn, future perspectives are delineated, and annexes are included.La presente tesis doctoral, concebida principalmente para apoyar y reforzar la relación entre la academia y la industria, se desarrolló en colaboración con Shell Global Solutions (Amsterdam, Países Bajos) en el esfuerzo de aplicar y posiblemente extender los enfoques ya consolidados basados en variables latentes (es decir, Análisis de Componentes Principales - PCA - Regresión en Mínimos Cuadrados Parciales - PLS - o PLS discriminante - PLSDA) para la resolución de problemas complejos no sólo en los campos de mejora y optimización de procesos, sino también en el entorno más amplio del análisis de datos multivariados. Con este fin, en todos los capítulos proponemos nuevas soluciones algorítmicas eficientes para abordar tareas dispares, desde la transferencia de calibración en espectroscopia hasta el modelado en tiempo real de flujos de datos. El manuscrito se divide en las seis partes siguientes, centradas en diversos temas de interés: Parte I - Prefacio, donde presentamos un resumen de este trabajo de investigación, damos sus principales objetivos y justificaciones junto con una breve introducción sobre PCA, PLS y PLSDA; Parte II - Sobre las extensiones basadas en kernels de PCA, PLS y PLSDA, donde presentamos el potencial de las técnicas de kernel, eventualmente acopladas a variantes específicas de la recién redescubierta proyección de pseudo-muestras, formulada por el estadista inglés John C. Gower, y comparamos su rendimiento respecto a metodologías más clásicas en cuatro aplicaciones a escenarios diferentes: segmentación de imágenes Rojo-Verde-Azul (RGB), discriminación y monitorización de procesos por lotes y análisis de diseños de experimentos de mezclas; Parte III - Sobre la selección del número de factores en el PCA por pruebas de permutación, donde aportamos una guía extensa sobre cómo conseguir la selección de componentes de PCA mediante pruebas de permutación y una ilustración completa de un procedimiento algorítmico original implementado para tal fin; Parte IV - Sobre la modelización de fuentes de variabilidad común y distintiva en el análisis de datos multi-conjunto, donde discutimos varios aspectos prácticos del análisis de componentes comunes y distintivos de dos bloques de datos (realizado por métodos como el Análisis Simultáneo de Componentes - SCA - Análisis Simultáneo de Componentes Distintivos y Comunes - DISCO-SCA - Descomposición Adaptada Generalizada de Valores Singulares - Adapted GSVD - ECO-POWER, Análisis de Correlaciones Canónicas - CCA - y Proyecciones Ortogonales de 2 conjuntos a Estructuras Latentes - O2PLS). Presentamos a su vez una nueva estrategia computacional para determinar el número de factores comunes subyacentes a dos matrices de datos que comparten la misma dimensión de fila o columna y dos planteamientos novedosos para la transferencia de calibración entre espectrómetros de infrarrojo cercano; Parte V - Sobre el procesamiento y la modelización en tiempo real de flujos de datos de alta dimensión, donde diseñamos la herramienta de Procesamiento en Tiempo Real (OTFP), un nuevo sistema de manejo racional de mediciones multi-canal registradas en tiempo real; Parte VI - Epílogo, donde presentamos las conclusiones finales, delimitamos las perspectivas futuras, e incluimos los anexos.La present tesi doctoral, concebuda principalment per a recolzar i reforçar la relació entre l'acadèmia i la indústria, es va desenvolupar en col·laboració amb Shell Global Solutions (Amsterdam, Països Baixos) amb l'esforç d'aplicar i possiblement estendre els enfocaments ja consolidats basats en variables latents (és a dir, Anàlisi de Components Principals - PCA - Regressió en Mínims Quadrats Parcials - PLS - o PLS discriminant - PLSDA) per a la resolució de problemes complexos no solament en els camps de la millora i optimització de processos, sinó també en l'entorn més ampli de l'anàlisi de dades multivariades. A aquest efecte, en tots els capítols proposem noves solucions algorítmiques eficients per a abordar tasques dispars, des de la transferència de calibratge en espectroscopia fins al modelatge en temps real de fluxos de dades. El manuscrit es divideix en les sis parts següents, centrades en diversos temes d'interès: Part I - Prefaci, on presentem un resum d'aquest treball de recerca, es donen els seus principals objectius i justificacions juntament amb una breu introducció sobre PCA, PLS i PLSDA; Part II - Sobre les extensions basades en kernels de PCA, PLS i PLSDA, on presentem el potencial de les tècniques de kernel, eventualment acoblades a variants específiques de la recentment redescoberta projecció de pseudo-mostres, formulada per l'estadista anglés John C. Gower, i comparem el seu rendiment respecte a metodologies més clàssiques en quatre aplicacions a escenaris diferents: segmentació d'imatges Roig-Verd-Blau (RGB), discriminació i monitorització de processos per lots i anàlisi de dissenys d'experiments de mescles; Part III - Sobre la selecció del nombre de factors en el PCA per proves de permutació, on aportem una guia extensa sobre com aconseguir la selecció de components de PCA a través de proves de permutació i una il·lustració completa d'un procediment algorítmic original implementat per a la finalitat esmentada; Part IV - Sobre la modelització de fonts de variabilitat comuna i distintiva en l'anàlisi de dades multi-conjunt, on discutim diversos aspectes pràctics de l'anàlisis de components comuns i distintius de dos blocs de dades (realitzat per mètodes com l'Anàlisi Simultània de Components - SCA - Anàlisi Simultània de Components Distintius i Comuns - DISCO-SCA - Descomposició Adaptada Generalitzada en Valors Singulars - Adapted GSVD - ECO-POWER, Anàlisi de Correlacions Canòniques - CCA - i Projeccions Ortogonals de 2 blocs a Estructures Latents - O2PLS). Presentem al mateix temps una nova estratègia computacional per a determinar el nombre de factors comuns subjacents a dues matrius de dades que comparteixen la mateixa dimensió de fila o columna, i dos plantejaments nous per a la transferència de calibratge entre espectròmetres d'infraroig proper; Part V - Sobre el processament i la modelització en temps real de fluxos de dades d'alta dimensió, on dissenyem l'eina de Processament en Temps Real (OTFP), un nou sistema de tractament racional de mesures multi-canal registrades en temps real; Part VI - Epíleg, on presentem les conclusions finals, delimitem les perspectives futures, i incloem annexos.Vitale, R. (2017). Novel chemometric proposals for advanced multivariate data analysis, processing and interpretation [Tesis doctoral no publicada]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/90442TESI