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Modern industrial plants are usually large scaled and contain a great amount of sensors. Sensor fault diagnosis is crucial and necessary to process safety and optimal operation. This paper proposes a systematic approach to detect, isolate and identify multiple sensor faults for multivariate dynamic systems. The current work first defines deviation vectors for sensor observations, and further defines and derives the basic sensor fault matrix (BSFM), consisting of the normalized basic fault vectors, by several different methods. By projecting a process deviation vector to the space spanned by BSFM, this research uses a vector with the resulted weights on each direction for multiple sensor fault diagnosis. This study also proposes a novel monitoring index and derives corresponding sensor fault detectability. The study also utilizes that vector to isolate and identify multiple sensor faults, and discusses the isolatability and identifiability. Simulation examples and comparison with two conventional PCA-based contribution plots are presented to demonstrate the effectiveness of the proposed methodology.
ISA Trans 2010 Oct
PMID:Multiple sensor fault diagnosis for dynamic processes. 2054 68

This paper proposes the development of water sample classification and authentication, in real life which is based on machine learning algorithms. The proposed techniques used experimental measurements from a pulse voltametry method which is based on an electronic tongue (E-tongue) instrumentation system with silver and platinum electrodes. E-tongue include arrays of solid state ion sensors, transducers even of different types, data collectors and data analysis tools, all oriented to the classification of liquid samples and authentication of unknown liquid samples. The time series signal and the corresponding raw data represent the measurement from a multi-sensor system. The E-tongue system, implemented in a laboratory environment for 6 numbers of different ISI (Bureau of Indian standard) certified water samples (Aquafina, Bisleri, Kingfisher, Oasis, Dolphin, and McDowell) was the data source for developing two types of machine learning algorithms like classification and regression. A water data set consisting of 6 numbers of sample classes containing 4402 numbers of features were considered. A PCA (principal component analysis) based classification and authentication tool was developed in this study as the machine learning component of the E-tongue system. A proposed partial least squares (PLS) based classifier, which was dedicated as well; to authenticate a specific category of water sample evolved out as an integral part of the E-tongue instrumentation system. The developed PCA and PLS based E-tongue system emancipated an overall encouraging authentication percentage accuracy with their excellent performances for the aforesaid categories of water samples.
ISA Trans 2011 Jul
PMID:Classification and authentication of unknown water samples using machine learning algorithms. 2150

Turbulence simulation methods are of fundamental importance for evaluating the performance of control strategies for Adaptive Optics (AO) systems. In order to obtain a reliable evaluation of the performance a statistically accurate turbulence simulation method has to be used. This work generalizes a previously proposed method for turbulence simulation based on the use of a multiscale stochastic model. The main contributions of this work are: first, a multiresolution local PCA representation is considered. In typical operating conditions, the computational load for turbulence simulation is reduced approximately by a factor of 4, with respect to the previously proposed method, by means of this PCA representation. Second, thanks to a different low resolution method, based on a moving average model, the wind velocity can be in any direction (not necessarily that of the spatial axes). Finally, this paper extends the simulation procedure to generate, if needed, turbulence samples by using a more general model than that of the frozen flow hypothesis.
ISA Trans 2014 Sep
PMID:Nonstationary multiscale turbulence simulation based on local PCA. 2441 75

Multiblock principal component analysis (MBPCA) methods are gaining increasing attentions in monitoring plant-wide processes. Generally, MBPCA assumes that some process knowledge is incorporated for block division; however, process knowledge is not always available. A new totally data-driven MBPCA method, which employs mutual information (MI) to divide the blocks automatically, has been proposed. By constructing sub-blocks using MI, the division not only considers linear correlations between variables, but also takes into account non-linear relations thereby involving more statistical information. The PCA models in sub-blocks reflect more local behaviors of process, and the results in all blocks are combined together by support vector data description. The proposed method is implemented on a numerical process and the Tennessee Eastman process. Monitoring results demonstrate the feasibility and efficiency.
ISA Trans 2014 Sep
PMID:Plant-wide process monitoring based on mutual information-multiblock principal component analysis. 2495 77

Principal component analysis has been widely used in the process industries for the purpose of monitoring abnormal behaviour. The process of reducing dimension is obtained through PCA, while T-tests are used to test for abnormality. Some of the main contributions to the success of PCA is its ability to not only detect problems, but to also give some indication as to where these problems are located. However, PCA and the T-test make use of Gaussian assumptions which may not be suitable in process fault detection. A previous modification of this method is the use of independent component analysis (ICA) for dimension reduction combined with kernel density estimation for detecting abnormality; like PCA, this method points out location of the problems based on linear data-driven methods, but without the Gaussian assumptions. Both ICA and PCA, however, suffer from challenges in interpreting results, which can make it difficult to quickly act once a fault has been detected online. This paper proposes the use of Bayesian networks for dimension reduction which allows the use of process knowledge enabling more intelligent dimension reduction and easier interpretation of results. The dimension reduction technique is combined with multivariate kernel density estimation, making this technique effective for non-linear relationships with non-Gaussian variables. The performance of PCA, ICA and Bayesian networks are compared on data from an industrial scale plant.
ISA Trans 2015 Sep
PMID:Process monitoring using kernel density estimation and Bayesian networking with an industrial case study. 2593 Feb 33

A clustering problem involving multivariate time series (MTS) requires the selection of similarity metrics. This paper shows the limitations of the PCA similarity factor (SPCA) as a single metric in nonlinear problems where there are differences in magnitude of the same process variables due to expected changes in operation conditions. A novel method for clustering MTS based on a combination between SPCA and the average-based Euclidean distance (AED) within a fuzzy clustering approach is proposed. Case studies involving either simulated or real industrial data collected from a large scale gas turbine are used to illustrate that the hybrid approach enhances the ability to recognize normal and fault operating patterns. This paper also proposes an oversampling procedure to create synthetic multivariate time series that can be useful in commonly occurring situations involving unbalanced data sets.
ISA Trans 2017 Nov
PMID:A hybrid clustering approach for multivariate time series - A case study applied to failure analysis in a gas turbine. 2892 43

This paper presents an improved incipient fault detection method based on Kullback-Leibler (KL) divergence under multivariate statistical analysis frame. Different from the traditional multivariate fault detection methods, this methodology can detect slight anomalous behaviors by comparing the online probability density function (PDF) online with the reference PDF obtained from large scale off-line data set. In the principal and residual subspaces obtained via PCA, a symmetric evaluation function is defined for both single variate and multivariate cases. The uniform form of probability distribution and fault detection thresholds associated with all eigenvalues are given. In addition, the robust performance is analyzed with respect to a wide range of Signal to Noise Ratio (SNR). Case studies are conducted with three types of incipient faults on a numerical example; combining with two nonlinear projections, the proposed scheme is successfully used for incipient fault detection in non-Gaussian electrical drive system. The results can demonstrate the superiority of the proposed method than several other methods.
ISA Trans 2018 Aug
PMID:An improved incipient fault detection method based on Kullback-Leibler divergence. 2980 23

Multiblock methods have been proposed to capture the complex characteristics of plant-wide monitoring due to the enlargement of process industries. These methods based on automatic sub-block division and copula-correlation, which simultaneously describe the correlation degree and correlation patterns, are designed for sub-block partition. However, the selection of variables for each sub-block through copula-correlation analysis requires a pre-defined cutoff parameter which is difficult to be determined without sufficient prior knowledge, and a "bad" parameter leads to a degraded performance. Therefore, a weighted copula-correlation-based multiblock principal component analysis (WCMBPCA) is proposed. First, the variables in each sub-block are obtained through the copula-correlation analysis-based weighted strategy rather than the cutoff parameter, which highly avoids information loss and prevents "noisy" information. Second, a PCA model is established in each sub-block. Third, a Bayesian inference strategy is used to merge the monitoring results of all sub-blocks. Finally, an online-horizon Bayesian fault diagnosis system is established to identify the fault type of the system based on the statistics of each sub-block. The average detection rate and the average diagnosis rate for numerical example are 77.85% and 98.95%, and that for TE example are 80.63% and 89.50%. Comparing with other candidate methods, the proposed method achieves excellent detection and diagnostic performance.
ISA Trans 2020 Jan
PMID:Plant-wide process monitoring by using weighted copula-correlation based multiblock principal component analysis approach and online-horizon Bayesian method. 3135 45