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

Anomaly detection and mode identification in multimode processes using the field Kalman filter

A process plant can have multiple modes of operation due to varying demand, availability of resources or the fundamental design of a process. Each of these modes is considered as normal operation. Anomalies in the process are characterised as deviations away from normal operation. Such anomalies can be indicative of developing faults which, if left unresolved, can lead to failures and unplanned downtime. The Field Kalman Filter (FKF) is a model-based approach, which is adopted in this paper for monitoring a multimode process. Previously, the FKF has been applied in process monitoring to differentiate normal operation from known faulty modes of operation. This paper extends the FKF so that it may detect occurrences of anomalies and differentiate them from the various normal modes of operation. A method is proposed for offline training an FKF monitoring model and on-line monitoring. The off-line part comprises training an FKF model based on Multivariate Autoregressive State-Space (MARSS) models fitted to historical process data. A monitoring indicator is also introduced. On-line monitoring, on the basis of the FKF for anomaly detection and mode identification, is demonstrated using a simulated multimode process. The performance of the proposed method is also demonstrated using data obtained from a pilot scale multiphase flow facility. The results show that the method can be applied successfully for anomaly detection and mode identification

Non-stationary discrete convolution kernel for multimodal process monitoring

Data-driven process monitoring has benefited from the development and application of kernel transformations, especially when various types of nonlinearity exist in the data. However, when dealing with the multimodality behavior which is frequently observed in process operations, the most widely used Radial Basis Function kernel has limitations in describing process data collected from multiple normal operating modes. In this paper, we highlight this limitation via a synthesized example. In order to account for the multimodality behavior and improve fault detection performance accordingly, we propose a novel Non-stationary Discrete Convolution kernel, which derives from the convolution kernel structure, as an alternative to the RBF kernel. By assuming the training samples to be the support of the discrete convolution, this new kernel can properly address these training samples from different operating modes with diverse properties, and therefore can improve the data description and fault detection performance. Its performance is compared with RBF kernels under a standard kernel PCA framework and with other methods proposed for multimode process monitoring via numerical examples. Moreover, a benchmark data set collected from a pilot-scale multiphase flow facility is used to demonstrate the advantages of the new kernel when applied to an experimental data set

CVABS: Moving Object Segmentation with Common Vector Approach for Videos

Background modelling is a fundamental step for several real-time computer vision applications that requires security systems and monitoring. An accurate background model helps detecting activity of moving objects in the video. In this work, we have developed a new subspace based background modelling algorithm using the concept of Common Vector Approach with Gram-Schmidt orthogonalization. Once the background model that involves the common characteristic of different views corresponding to the same scene is acquired, a smart foreground detection and background updating procedure is applied based on dynamic control parameters. A variety of experiments is conducted on different problem types related to dynamic backgrounds. Several types of metrics are utilized as objective measures and the obtained visual results are judged subjectively. It was observed that the proposed method stands successfully for all problem types reported on CDNet2014 dataset by updating the background frames with a self-learning feedback mechanism.Comment: 12 Pages, 4 Figures, 1 Tabl

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

Multimode system condition monitoring using sparsity reconstruction for quality control

In this paper, we introduce an improved multivariate statistical monitoring method based on the stacked sparse autoencoder (SSAE). Our contribution focuses on the choice of the SSAE model based on neural networks to solve diagnostic problems of complex systems. In order to monitor the process performance, the squared prediction error (SPE) chart is linked with nonparametric adaptive confidence bounds which arise from the kernel density estimation to minimize erroneous alerts. Then, faults are localized using two methods: contribution plots and sensor validity index (SVI). The results are obtained from experiments and real data from a drinkable water processing plant, demonstrating how the applied technique is performed. The simulation results of the SSAE model show a better ability to detect and identify sensor failures

Multimode Process Monitoring Based on Sparse Principal Component Selection and Bayesian Inference-Based Probability

According to the demand for diversified products, modern industrial processes typically have multiple operating modes. At the same time, variables within the same mode often follow a mixture of Gaussian distributions. In this paper, a novel algorithm based on sparse principal component selection (SPCS) and Bayesian inference-based probability (BIP) is proposed for multimode process monitoring. SPCS can be formulated as a just-in-time regression between all PCs and each sample. SPCS selects PCs according to the nonzero regression coefficients which indicate the compact expression of the sample. This expression is necessarily discriminative: amongst all subset of PCs, SPCS selects the PCs which most compactly express the sample and rejects all other possible but less compact expressions. BIP is utilized to compute the posterior probabilities of each monitored sample belonging to the multiple components and derive an integrated global probabilistic index for fault detection of multimode processes. Finally, to verify its superiority, the SPCS-BIP algorithm is applied to the Tennessee Eastman (TE) benchmark process and a continuous stirred-tank reactor (CSTR) process