Fault detection in dynamic plant-wide process by multi-block slow feature analysis and support vector data description

Accurate monitoring of complex industrial plants is crucial for ensuring safe operations and reliable management of desired quality. Early detection of abnormal events is essential to preempt serious consequences, enhance system performance, and reduce manufacturing costs. In this work, we propose a novel methodology for fault detection based on Slow Feature Analysis (SFA) tailored for time series models and statistical process control. Fault detection is critical in process monitoring and can ensure that systems operate efficiently and safely. This study investigates the effectiveness of various multivariate statistical methods, including Slow Feature Analysis (SFA), Kernel Slow Feature Analysis (KSFA), Dynamic Slow Feature Analysis (DSFA), and Principal Component Analysis (PCA) in detecting faults within the Tennessee Eastman (TE), Benchmark Simulation Model No. 1 (BSM 1) datasets and Beijing wastewater treatment plant (real world). Our comprehensive analysis indicates that KSFA and DSFA significantly outperform traditional methods by providing enhanced sensitivity and fault detection capabilities, particularly in complex, nonlinear, and dynamic data environments. The comparative analysis underscores the superior performance of KSFA and DSFA in capturing comprehensive process behavior, making them robust, cutting-edge choices for advanced fault detection applications. Such methodologies promise substantial improvements in industrial plant monitoring, contributing to heightened system reliability, safety, and overall operational efficiency.

Slow feature analysis-independent component analysis based integrated monitoring approach for industrial processes incorporating dynamic and static characteristics

Support vector data description (SVDD) is an effective algorithm for nonlinear process monitoring. However, the conventional SVDD method can't deal with the incipient faults well, which has the small fault amplitude and is easy to be overlapped by industrial noises. Aiming at this problem, an improved SVDD, called probability related SVDD in local variable field (LVPSVDD), is proposed to detect the incipient faults in nonlinear processes. Firstly, the method divides process variables into several local variable fields by hierarchical clustering, and the SVDD model of each variable field is built. Then the sliding window technology is applied to the SVDD distance statistics, and the probability distribution change in the sliding window is measured by Kullback Leibler divergence (KLD). For each local variable field, the corresponding probability related monitoring statistic is developed to replace the original distance statistic. Finally, the global monitoring statistic is obtained by integrating the monitoring results of all local variable fields with Bayesian inference strategy. The method is illustrated with simulation on the continuous stirred tank reactor (CSTR).

As one classical anomaly detection technology, support vector data description (SVDD) has been successfully applied to nonlinear chemical process monitoring. However, the basic SVDD model cannot achieve a satisfactory fault detection performance in the complicated cases because of its intrinsic shallow learning structure. Motivated by the deep learning theory, one improved SVDD method, called ensemble deep SVDD (EDeSVDD), is proposed in order to monitor the process faults more effectively. In the proposed method, a deep support vector data description (DeSVDD) framework is firstly constructed by introducing the deep feature extraction procedure. Different to the traditional SVDD with only one feature extraction layer, DeSVDD is designed with multi-layer feature extraction structure and optimized by minimizing the data-enclosing hypersphere with the regularization of the deep network weights. Further considering the problem that DeSVDD monitoring performance is easily affected by the model structure and the initial weight parameters, an ensemble DeSVDD (EDeSVDD) is presented by applying the ensemble learning strategy based on Bayesian inference. A series of DeSVDD sub-models are generated at the parameter level and the structure level, respectively. These two levels of sub-models are integrated for a holistic monitoring model. To identify the cause variables for the detected faults, a fault isolation scheme is designed by applying the distance correlation coefficients to measure the nonlinear dependency between the original variables and the holistic monitoring index. The applications to the Tennessee Eastman process demonstrate that the proposed EDeSVDD model outperforms the traditional SVDD model and the DeSVDD model in terms of fault detection performance and can identify the fault cause variables effectively.

Satellites play an increasingly crucial role in the economic and social development of the world. The momentum wheel is a key component of the satellite attitude control system, and its reliability is an important factor affecting the lifespan of the satellite. Therefore, it is of great significance to detect the fault of the momentum wheel to improve the reliability and stability of the satellite. This paper proposes a fault detection method for satellite momentum wheels based on slow feature analysis (SFA) to detect different types of faults in the output data by extracting dynamic features. The momentum wheel simulation model is first constructed based on the working mechanism of the momentum wheel. From this model, a variety of actual failure types of momentum wheels are simulated, and high-dimensional data features are obtained. Then, SFA is used to extract rich dynamic features repre-senting the change process of high dimensional data. These features are used to construct static-dynamic statistics to complete online condition monitoring. The effectiveness and accuracy of the extracted method for fault detection have been demonstrated by simulation experiments. Finally, the research direction and future development of satellite momentum wheel fault detection based on SFA have been prospected.

This study focuses on the fault detection (FD) and false alarm rates (FAR) of Principal component analysis (PCA) and independent component analysis (ICA) algorithms on the Tennessee Eastman (TE) process. However, PCA and ICA algorithms have been applied widely to systems for data driven fault detection, there are limited work on FARs of the algorithms. In this work, FARs of the algorithms are investigated on TE process. Simulation study indicates that the proposed algorithms are robust for fault detection, and ICA has higher performance than PCA for FARs.

In this study, a system for faults detection using a combination of Support Vector Data Description (SVDD) with metaheuristic algorithms is presented. The presented approach is applied to a real industrial process where the set of measured faults is scarce. The original contribution in this work is the industrial context of application and the comparison of swarm intelligence algorithms to optimize the SVDD hyper-parameters. Four recent metaheuristics are compared hereby to solve the corresponding optimization problem in an efficient manner. These optimization techniques are then implemented for fault detection in a multivariate industrial process with non-balanced data. The obtained numerical results seem to be promising when the considered optimization techniques are combined with SVDD. In particular, the Spotted Hyena algorithm outperforms other metaheuristics reaching values of F1 score near 100% in fault detection.

We propose an approach to fault detection in rotating mechanical machines: fusion of multichannel measurements of machine vibration using independent component analysis (ICA), followed by a description of the admissible domain (part of the feature space indicative of normal machine operation) with a support vector domain description (SVDD) method. The SVDD method enables the determination of an arbitrary shaped region that comprises a target class of a dataset. In this particular application, it provides a way to quantify the compactness of the admissible class in relation to data preprocessing. Application to monitoring of a submersible pump indicates that combination of measurement channels with ICA gives improved results in fault detection, without requiring detailed prior knowledge on origin and type of the failure.

Fault detection based on the vibration signal of an engine is an effective non-disassembly method for engine diagnosis because a vibration signal includes a lot of information about the condition of the engine. To obtain multi-information for this article, three vibration sensors were placed at different test points to collect vibration information about the engine operating process. A method combining support vector data description and Dempster–Shafer evidence theory was developed for engine fault detection, where support vector data description is used to recognize the data from a single sensor and Dempster–Shafer evidence theory is used to classify the information from the three vibration sensors in detail. The experimental results show that the fault detection accuracy using three sensors is higher than using a single sensor. The multi-complementary sensor information can be adopted in the proposed method, which will increase the reliability of fault detection and reduce uncertainty in the recognition of a fault.

Detection and classification are two significant tasks for industrial fault diagnosis. However, conventional methods typically treat these tasks as separate and independent problems, and necessitate a retraining process when new fault samples or classes are collected. Therefore, an incremental support vector data description scheme using Gaussian kernel function is pro-posed for industrial process fault diagnosis in a unified frame-work. In this framework, the decision boundary is updated incrementally only based on the specific original support vectors and newly collected samples. An adaptive threshold and a restructured radius are proposed to promote accuracy in the fault detection. In the classification procedure, the hyperspheres for all known classes are constructed by decision tree. The new sample that does not belong to any known class is identified as an unknown class. Without a time-consuming retraining process, the proposed diagnosis method with the incremental learning capability can synchronously achieve the fault detection and classification task. Experimental results demonstrate the effectiveness and superiority in terms of diagnosis performance. <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">Note to Practitioners</i> —In practical industrial processes, new fault samples are collected and new fault classes emerge continually. Under such scenarios, fault diagnosis with incremental learning capability is becoming increasingly important. This work proposes a unified incremental framework for fault diagnosis based on support vector data description, which is able to achieve fault detection and classification synchronously. For fault detection, an adaptive threshold and a restructured radius are developed. For fault classification, hypersphere-shaped boundaries of all fault classes are given via the decision tree-based strategy. The proposed method is updated to include new fault samples and fault classes without dimensionality reduction or any distributional assumptions.

Plant-wide process monitoring based on mutual information–multiblock principal component analysis

Modern industry processes are typically composed of multiple operating units with reaction interaction and energy-mass coupling, which result in a mixed time-varying and spatial-temporal coupling of process variables. It is challenging to develop a comprehensive and precise fault detection model for the multiple interconnected units by simple superposition of the individual unit models. In this study, the fault detection problem is formulated as a spatial-temporal fault detection problem utilizing process data of multiple interconnected unit processes. A spatial-temporal variational graph attention autoencoder (STVGATE) using interactive information is proposed for fault detection, which aims to effectively capture the spatial and temporal features of the interconnected unit processes. First, slow feature analysis (SFA) is implemented to extract temporal information that reveals the dynamic relevance of the process data. Then, an integration method of metric learning and prior knowledge is proposed to construct coupled spatial relationships based on temporal information. In addition, a variational graph attention autoencoder (VGATE) is suggested to extract temporal and spatial information for fault detection, which incorporates the dominances of variational inference and graph attention mechanisms. The proposed method can automatically extract and deeply mine spatial-temporal interactive feature information to boost detection performance. Finally, three industrial process experiments are performed to verify the feasibility and effectiveness of the proposed method. The results demonstrate that the proposed method dramatically increases the fault detection rate (FDR) and reduces the false alarm rate (FAR).

It is of critical importance to keep a steady operation in the blast furnace to facilitate the production of high quality hot metal. In order to monitor the state of blast furnace, this article proposes a fault detection and identification method based on the multidimensional Gated Recurrent Unit (GRU) network, which is a kind of recurrent neural network and is highly effective in handling process dynamics. Comparing to conventional recurrent neural networks, GRU has a simpler structure and involves fewer parameters. In fault detection, a moving window approach is applied and a GRU model is constructed for each process variable to generate a series of residuals, which is further monitored using the support vector data description (SVDD) method. Once a fault is detected, fault identification is performed using the contribution analysis. Application to a real blast furnace fault shows that the proposed method is effective.

Monitoring and management of process transitions is a critical activity in chemical plants due to increased potential for abnormal operations. This activity is often hampered by the lack of a proper approach to label the transition states. In this paper, we present a systematic framework that constructs process transition states thus facilitating their monitoring for faulty operations. To address the nonstationary and non-Gaussian characteristics of the time series data collected during the transition process, an ensemble clustering method based on dynamic k-principal component analysis-independent component analysis (k-ICA-PCA) models is proposed to enable labeling of transitions. Next, we combine a PCA-based dimension reduction with a pattern classification strategy based on multiclass support vector data description (SVDD) to achieve transition process monitoring. The Tennessee Eastman (TE) benchmark process is used as a case study to evaluate the performance of the proposed framework.

The self-attention mechanism has advantages in analyzing the internal characteristics of data and capturing local information. Therefore, it is applied to fault detection. Since complex industrial processes usually contain a mixture of properties, such as nonlinearity, dynamics, and non-Gaussianity, this places higher demands on fault detection methods. To further improve the performance of the self-attention mechanism for fault detection in complex industrial processes, an innovative self-attention mechanism integrating the adaptive double subspace (ISA-ADS) method is proposed for fault detection. First, the query matrix, the key matrix, and the value matrix of the self-attention mechanism are designed so that they can better focus on local information through the adaptive sample weight allocation strategy. At the same time, this design reduces the interference of nonlinear and noisy information and amplifies the impact of important fault information in the sample. Second, considering the problem of Gaussian and non-Gaussian distributions of the data and the different degrees of influence of different subspaces on the final process monitoring results, an adaptive Gaussian and non-Gaussian double subspace fault detection model based on the self-attention output matrix is established, which adaptively assigns different weights to different subspaces by determining their importance. The statistics of different subspaces are fused using the Bayesian inference and a new adaptive monitoring statistic is constructed to obtain a more accurate monitoring of the process state. Finally, the ISA-ADS is validated using the Tennessee Eastman (TE) process and the actual polyethylene production process. The results show that ISA-ADS has a low false alarm rate and a high fault detection rate, verifying the effectiveness of its fault detection performance.