A Novel Ensemble Adaptive Sparse Bayesian Transfer Learning Machine for Nonlinear Large-Scale Process Monitoring.

Process monitoring plays an important role in ensuring the safety and stable operation of equipment in a large-scale process. This paper proposes a novel data-driven process monitoring framework, termed the ensemble adaptive sparse Bayesian transfer learning machine (EAdspB-TLM), for nonlinear fault diagnosis. The proposed framework has the following advantages: Firstly, the probabilistic relevance vector machine (PrRVM) under Bayesian framework is re-derived so that it can be used to forecast the plant operating conditions. Secondly, we extend the PrRVM method and assimilate transfer learning into the sparse Bayesian learning framework to provide it with the transferring ability. Thirdly, the source domain (SD) data are re-enabled to alleviate the issue of insufficient training data. Finally, the proposed EAdspB-TLM framework was effectively applied to monitor a real wastewater treatment process (WWTP) and a Tennessee Eastman chemical process (TECP). The results further demonstrate that the proposed method is feasible

Nonlinear data driven techniques for process monitoring

The goal of this research is to develop process monitoring technology capable of taking advantage of the large stores of data accumulating in modern chemical plants. There is demand for new techniques for the monitoring of non-linear topology and behavior, and this research presents a topological preservation method for process monitoring using Self Organizing Maps (SOM). The novel architecture presented adapts SOM to a full spectrum of process monitoring tasks including fault detection, fault identification, fault diagnosis, and soft sensing. The key innovation of the new technique is its use of multiple SOM (MSOM) in the data modeling process as well as the use of a Gaussian Mixture Model (GMM) to model the probability density function of classes of data. For comparison, a linear process monitoring technique based on Principal Component Analysis (PCA) is also used to demonstrate the improvements SOM offers. Data for the computational experiments was generated using a simulation of the Tennessee Eastman process (TEP) created in Simulink by (Ricker 1996). Previous studies focus on step changes from normal operations, but this work adds operating regimes with time dependent dynamics not previously considered with a SOM. Results show that MSOM improves upon both linear PCA as well as the standard SOM technique using one map for fault diagnosis, and also shows a superior ability to isolate which variables in the data are responsible for the faulty condition. With respect to soft sensing, SOM and MSOM modeled the compositions equally well, showing that no information was lost in dividing the map representation of process data. Future research will attempt to validate the technique on a real chemical process

Monitoring and detecting faults in wastewater treatment plants using deep learning

Wastewater treatment plants use many sensors to control energy consumption and discharge quality. These sensors produce a vast amount of data which can be efficiently monitored by automatic systems. Consequently, several different statistical and learning methods are proposed in the literature which can automatically detect faults. While these methods have shown promising results, the nonlinear dynamics and complex interactions of the variables in wastewater data necessitate more powerful methods with higher learning capacities. In response, this study focusses on modelling faults in the oxidation and nitrification process. Specifically, this study investigates a method based on deep neural networks (specifically, long short-term memory) compared with statistical and traditional machine-learning methods. The network is specifically designed to capture temporal behaviour of sensor data. The proposed method is evaluated on a real-life dataset containing over 5.1 million sensor data points. The method achieved a fault detection rate (recall) of over 92%, thus outperforming traditional methods and enabling timely detection of collective faults

Automatic outlier detection in automated water quality measurement stations

Des stations de mesure de la qualité de l’eau sont utilisées pour mesurer la qualité de l'eau à haute fréquence. Pour une gestion efficace de ces mesures, la qualité des données doit être vérifiée. Dans une méthode univariée précédemment développée, des points aberrants et des fautes étaient détectés dans les données mesurées par ces stations en employant des modèles à lissage exponentiel pour prédire les données au moment suivant avec l’intervalle de confiance. Dans la présente étude, ne considérant que le cas univarié, la détection de points aberrants est améliorée par l’identification d’un modèle autorégressif à moyenne mobile sur une fenêtre mobile de données pour prédire la donnée au moment suivant. Les données de turbidité mesurées à l'entrée d'une station d'épuration municipale au Danemark sont utilisées comme étude de cas pour comparer la performance de l’utilisation des deux modèles. Les résultats montrent que le nouveau modèle permet de prédire la donnée au moment suivant avec plus de précision. De plus, l’inclusion du nouveau modèle dans la méthode univariée présente une performance satisfaisante pour la détection de points aberrants et des fautes dans les données de l'étude de cas.Water quality monitoring stations are used to measure water quality at high frequency. For effective data management, the quality of the data must be evaluated. In a previously developed univariate method both outliers and faults were detected in the data measured by these stations by using exponential smoothing models that give one-step ahead forecasts and their confidence intervals. In the present study, the outlier detection step of the univariate method is improved by identifying an auto-regressive moving average model for a moving window of data and forecasting one-step ahead. The turbidity data measured at the inlet of a municipal treatment plant in Denmark is used as case study to compare the performance of the use of the two models. The results show that the forecasts made by the new model are more accurate. Also, inclusion of the new forecasting model in the univariate method shows satisfactory performance for detecting outliers and faults in the case study data

An investigation on automatic systems for fault diagnosis in chemical processes

Plant safety is the most important concern of chemical industries. Process faults can cause economic loses as well as human and environmental damages. Most of the operational faults are normally considered in the process design phase by applying methodologies such as Hazard and Operability Analysis (HAZOP). However, it should be expected that failures may occur in an operating plant. For this reason, it is of paramount importance that plant operators can promptly detect and diagnose such faults in order to take the appropriate corrective actions. In addition, preventive maintenance needs to be considered in order to increase plant safety. Fault diagnosis has been faced with both analytic and data-based models and using several techniques and algorithms. However, there is not yet a general fault diagnosis framework that joins detection and diagnosis of faults, either registered or non-registered in records. Even more, less efforts have been focused to automate and implement the reported approaches in real practice. According to this background, this thesis proposes a general framework for data-driven Fault Detection and Diagnosis (FDD), applicable and susceptible to be automated in any industrial scenario in order to hold the plant safety. Thus, the main requirement for constructing this system is the existence of historical process data. In this sense, promising methods imported from the Machine Learning field are introduced as fault diagnosis methods. The learning algorithms, used as diagnosis methods, have proved to be capable to diagnose not only the modeled faults, but also novel faults. Furthermore, Risk-Based Maintenance (RBM) techniques, widely used in petrochemical industry, are proposed to be applied as part of the preventive maintenance in all industry sectors. The proposed FDD system together with an appropriate preventive maintenance program would represent a potential plant safety program to be implemented. Thus, chapter one presents a general introduction to the thesis topic, as well as the motivation and scope. Then, chapter two reviews the state of the art of the related fields. Fault detection and diagnosis methods found in literature are reviewed. In this sense a taxonomy that joins both Artificial Intelligence (AI) and Process Systems Engineering (PSE) classifications is proposed. The fault diagnosis assessment with performance indices is also reviewed. Moreover, it is exposed the state of the art corresponding to Risk Analysis (RA) as a tool for taking corrective actions to faults and the Maintenance Management for the preventive actions. Finally, the benchmark case studies against which FDD research is commonly validated are examined in this chapter. The second part of the thesis, integrated by chapters three to six, addresses the methods applied during the research work. Chapter three deals with the data pre-processing, chapter four with the feature processing stage and chapter five with the diagnosis algorithms. On the other hand, chapter six introduces the Risk-Based Maintenance techniques for addressing the plant preventive maintenance. The third part includes chapter seven, which constitutes the core of the thesis. In this chapter the proposed general FD system is outlined, divided in three steps: diagnosis model construction, model validation and on-line application. This scheme includes a fault detection module and an Anomaly Detection (AD) methodology for the detection of novel faults. Furthermore, several approaches are derived from this general scheme for continuous and batch processes. The fourth part of the thesis presents the validation of the approaches. Specifically, chapter eight presents the validation of the proposed approaches in continuous processes and chapter nine the validation of batch process approaches. Chapter ten raises the AD methodology in real scaled batch processes. First, the methodology is applied to a lab heat exchanger and then it is applied to a Photo-Fenton pilot plant, which corroborates its potential and success in real practice. Finally, the fifth part, including chapter eleven, is dedicated to stress the final conclusions and the main contributions of the thesis. Also, the scientific production achieved during the research period is listed and prospects on further work are envisaged.La seguridad de planta es el problema más inquietante para las industrias químicas. Un fallo en planta puede causar pérdidas económicas y daños humanos y al medio ambiente. La mayoría de los fallos operacionales son previstos en la etapa de diseño de un proceso mediante la aplicación de técnicas de Análisis de Riesgos y de Operabilidad (HAZOP). Sin embargo, existe la probabilidad de que pueda originarse un fallo en una planta en operación. Por esta razón, es de suma importancia que una planta pueda detectar y diagnosticar fallos en el proceso y tomar las medidas correctoras adecuadas para mitigar los efectos del fallo y evitar lamentables consecuencias. Es entonces también importante el mantenimiento preventivo para aumentar la seguridad y prevenir la ocurrencia de fallos. La diagnosis de fallos ha sido abordada tanto con modelos analíticos como con modelos basados en datos y usando varios tipos de técnicas y algoritmos. Sin embargo, hasta ahora no existe la propuesta de un sistema general de seguridad en planta que combine detección y diagnosis de fallos ya sea registrados o no registrados anteriormente. Menos aún se han reportado metodologías que puedan ser automatizadas e implementadas en la práctica real. Con la finalidad de abordar el problema de la seguridad en plantas químicas, esta tesis propone un sistema general para la detección y diagnosis de fallos capaz de implementarse de forma automatizada en cualquier industria. El principal requerimiento para la construcción de este sistema es la existencia de datos históricos de planta sin previo filtrado. En este sentido, diferentes métodos basados en datos son aplicados como métodos de diagnosis de fallos, principalmente aquellos importados del campo de “Aprendizaje Automático”. Estas técnicas de aprendizaje han resultado ser capaces de detectar y diagnosticar no sólo los fallos modelados o “aprendidos”, sino también nuevos fallos no incluidos en los modelos de diagnosis. Aunado a esto, algunas técnicas de mantenimiento basadas en riesgo (RBM) que son ampliamente usadas en la industria petroquímica, son también propuestas para su aplicación en el resto de sectores industriales como parte del mantenimiento preventivo. En conclusión, se propone implementar en un futuro no lejano un programa general de seguridad de planta que incluya el sistema de detección y diagnosis de fallos propuesto junto con un adecuado programa de mantenimiento preventivo. Desglosando el contenido de la tesis, el capítulo uno presenta una introducción general al tema de esta tesis, así como también la motivación generada para su desarrollo y el alcance delimitado. El capítulo dos expone el estado del arte de las áreas relacionadas al tema de tesis. De esta forma, los métodos de detección y diagnosis de fallos encontrados en la literatura son examinados en este capítulo. Asimismo, se propone una taxonomía de los métodos de diagnosis que unifica las clasificaciones propuestas en el área de Inteligencia Artificial y de Ingeniería de procesos. En consecuencia, se examina también la evaluación del performance de los métodos de diagnosis en la literatura. Además, en este capítulo se revisa y reporta el estado del arte correspondiente al “Análisis de Riesgos” y a la “Gestión del Mantenimiento” como técnicas complementarias para la toma de medidas correctoras y preventivas. Por último se abordan los casos de estudio considerados como puntos de referencia en el campo de investigación para la aplicación del sistema propuesto. La tercera parte incluye el capítulo siete, el cual constituye el corazón de la tesis. En este capítulo se presenta el esquema o sistema general de diagnosis de fallos propuesto. El sistema es dividido en tres partes: construcción de los modelos de diagnosis, validación de los modelos y aplicación on-line. Además incluye un modulo de detección de fallos previo a la diagnosis y una metodología de detección de anomalías para la detección de nuevos fallos. Por último, de este sistema se desglosan varias metodologías para procesos continuos y por lote. La cuarta parte de esta tesis presenta la validación de las metodologías propuestas. Específicamente, el capítulo ocho presenta la validación de las metodologías propuestas para su aplicación en procesos continuos y el capítulo nueve presenta la validación de las metodologías correspondientes a los procesos por lote. El capítulo diez valida la metodología de detección de anomalías en procesos por lote reales. Primero es aplicada a un intercambiador de calor escala laboratorio y después su aplicación es escalada a un proceso Foto-Fenton de planta piloto, lo cual corrobora el potencial y éxito de la metodología en la práctica real. Finalmente, la quinta parte de esta tesis, compuesta por el capítulo once, es dedicada a presentar y reafirmar las conclusiones finales y las principales contribuciones de la tesis. Además, se plantean las líneas de investigación futuras y se lista el trabajo desarrollado y presentado durante el periodo de investigación

Monitoring, diagnostics and improvement of process performance

The data generated in a chemical industry is a reflection of the process. With the modern computer control systems and data logging facilities, there is an increasing ability to collect large amounts of data. As there are many underlying aspects of the process in that data, with its proper utilization, it is possible to obtain useful information for process monitoring and fault diagnosis in addition to many other decision making activities. The purpose of this research is to utilize the data driven multivariate techniques of Principal Component Analysis (PCA) and Independent Component Analysis (ICA) for the estimation of process parameters. This research also includes analysis and comparison of these techniques for fault detection and diagnosis along with introduction, explanation and results from a new methodology developed in this research work namely Hybrid Independent Component Analysis (HICA).The first part of this research is the utilization of models of PCA and ICA for estimation of process parameters. The individual techniques of PCA and ICA are applied separately to the original data set of a waste water treatment plant (WWTP) and the process parameters for the unknown conditions of the process are calculated. For each of the techniques (PCA and ICA), the validation of the calculated parameters is carried out by construction of Decision Trees on WWTP dataset using inductive data mining and See 5.0. Both individual techniques were able to estimate all parameters successfully. The minor limitation in the validation of all results may be due to the strict application of these techniques to Gaussian and non-Gaussian data sets respectively. Using statistical analysis it was shown that the data set used in this work exhibits Gaussian and non-Gaussian behaviour.In the second part of this work multivariate techniques of Principal Component Analysis (PCA) and Independent Component Analysis (ICA) have been used for fault detection and diagnosis of a process along with introduction of the new technique, Hybrid Independent Component Analysis (HICA). The techniques are applied to two case studies, the waste water treatment plant (WWTP) and an Air pollution data set. As reported in literature, PCA and ICA proved to be useful tools for process monitoring on both data set, but a comparison of PCA and ICA along with the newly developed technique (HICA) illustrated the superiority of HICA over PCA and ICA. It is evident from the fact that PCA detected 74% and 67% of the faults in the WWTP data and Air pollution data set respectively. ICA successfully detected 61.3% and 62% of the faults from these datasets. Finally HICA showed improved results by the detection of 90% and 81% of the faults in both case studies. This showed that the new developed algorithm is more effective than the individual techniques of PCA and ICA. For fault diagnosis using PCA, ICA and HICA, contribution plots are constructed leading to the identification of responsible variable/s for a particular fault. This part also includes the work done for the estimation of process parameters using HICA technique as was done with PCA and ICA in the first part of the research. As expected HICA technique was more successful in estimation of parameters than PCA and ICA in line with its working for process monitoring