Multivariate statistical process monitoring and control (MSPM&C) methods for chemical process monitoring with statistical projection techniques such as principal component analysis (PCA) and partial least squares ...Multivariate statistical process monitoring and control (MSPM&C) methods for chemical process monitoring with statistical projection techniques such as principal component analysis (PCA) and partial least squares (PLS) are surveyed in this paper. The four-step procedure of performing MSPM&C for chemical process, modeling of processes, detecting abnormal events or faults, identifying the variable(s) responsible for the faults and diagnosing the source cause for the abnormal behavior, is analyzed. Several main research directions of MSPM&C reported in the literature are discussed, such as multi-way principal component analysis (MPCA) for batch process, statistical monitoring and control for nonlinear process, dynamic PCA and dynamic PLS, and on-line quality control by inferential models. Industrial applications of MSPM&C to several typical chemical processes, such as chemical reactor, distillation column, polymerization process, petroleum refinery units, are summarized. Finally, some concluding remarks and future considerations are made.展开更多
Chemical process variables are always driven by random noise and disturbances. The closed-loop con-trol yields process measurements that are auto and cross correlated. The influence of auto and cross correlations on s...Chemical process variables are always driven by random noise and disturbances. The closed-loop con-trol yields process measurements that are auto and cross correlated. The influence of auto and cross correlations on statistical process control (SPC) is investigated in detail by Monte Carlo experiments. It is revealed that in the sense of average performance, the false alarms rates (FAR) of principal component analysis (PCA), dynamic PCA are not affected by the time-series structures of process variables. Nevertheless, non-independent identical distribution will cause the actual FAR to deviate from its theoretic value apparently and result in unexpected consecutive false alarms for normal operating process. Dynamic PCA and ARMA-PCA are demonstrated to be inefficient to remove the influences of auto and cross correlations. Subspace identification-based PCA (SI-PCA) is proposed to improve the monitoring of dynamic processes. Through state space modeling, SI-PCA can remove the auto and cross corre-lations efficiently and avoid consecutive false alarms. Synthetic Monte Carlo experiments and the application in Tennessee Eastman challenge process illustrate the advantages of the proposed approach.展开更多
Fault detection and identification are challenging tasks in chemical processes, the aim of which is to decide out of control samples and find fault sensors timely and effectively. This paper develops a partitioning pr...Fault detection and identification are challenging tasks in chemical processes, the aim of which is to decide out of control samples and find fault sensors timely and effectively. This paper develops a partitioning principal component analysis(PPCA) method for process monitoring. A variable reasoning strategy is proposed and applied to recognize multiple fault variables. Compared with traditional process monitoring methods, the PPCA strategy not only reflects the local behavior of process variation in each model(each direction of principal components),but also improves the monitoring performance through the combination of local monitoring results. Then, a variable reasoning strategy is introduced to locate fault variables. Unlike the contribution plot, this method locates normal and fault variables effectively, and gives initiatory judgment for ambiguous variables. Finally, the effectiveness of the proposed process monitoring and fault variable identification schemes is verified through a numerical example and TE chemical process.展开更多
The kernel principal component analysis (KPCA) method employs the first several kernel principal components (KPCs), which indicate the most variance information of normal observations for process monitoring, but m...The kernel principal component analysis (KPCA) method employs the first several kernel principal components (KPCs), which indicate the most variance information of normal observations for process monitoring, but may not reflect the fault information. In this study, sensitive kernel principal component analysis (SKPCA) is proposed to improve process monitoring performance, i.e., to deal with the discordance of T2 statistic and squared prediction error SVE statistic and reduce missed detection rates. T2 statistic can be used to measure the variation di rectly along each KPC and analyze the detection performance as well as capture the most useful information in a process. With the calculation of the change rate of T2 statistic along each KPC, SKPCA selects the sensitive kernel principal components for process monitoring. A simulated simple system and Tennessee Eastman process are employed to demonstrate the efficiency of SKPCA on online monitoring. The results indicate that the monitoring performance is improved significantly.展开更多
Transporting hatching eggs from Hungary and incubating them abroad revealed lower hatchability compared to when the eggs were incubated in Hungary. Following transport, there were higher embryo losses and, notably, mo...Transporting hatching eggs from Hungary and incubating them abroad revealed lower hatchability compared to when the eggs were incubated in Hungary. Following transport, there were higher embryo losses and, notably, more malformed embryos. The aim of these initial trials was to determine if a testing device (crazy fit massage machine (CFM machine)) was able to replicate and model the mechanical impacts experienced during transport and reproduce the reduction in hatchability and increase the level of malformed embryos as observed in commercial practice. Tinytag~ high sensitivity shock and vibration loggers were used to monitor the impacts under field and trial conditions. Applying single 10 min treatments on the CFM machine, which used the same frequency (10-30 Hz) as the eggs experience under field conditions, induced the negative effect of transport, and lower hatching results were experienced. Three trials were conducted. Treated eggs in Trials 1 and 2 received automatically and periodical changing vibration in a range between 10-30 Hz for 10 min while in Trial 3 two different levels of impact were applied at 20 Hz and 30 Hz, respectively. Hatchability decreased due to the treatment significatly only in Trial 3. Significant differences were also detected in early dead levels in Trials 2 and 3 and the occurrences of malformation in Trials 1 and 3. All these results are in accordance with the field experience. Thus, the trials which examined the equipment were able to produce mechanical impacts that were repeatable in order to set up statistically reliable trials on hatching eggs.展开更多
基金Supported by the National High-Tech Development Program of China(No.863-511-920-011,2001AA411230).
文摘Multivariate statistical process monitoring and control (MSPM&C) methods for chemical process monitoring with statistical projection techniques such as principal component analysis (PCA) and partial least squares (PLS) are surveyed in this paper. The four-step procedure of performing MSPM&C for chemical process, modeling of processes, detecting abnormal events or faults, identifying the variable(s) responsible for the faults and diagnosing the source cause for the abnormal behavior, is analyzed. Several main research directions of MSPM&C reported in the literature are discussed, such as multi-way principal component analysis (MPCA) for batch process, statistical monitoring and control for nonlinear process, dynamic PCA and dynamic PLS, and on-line quality control by inferential models. Industrial applications of MSPM&C to several typical chemical processes, such as chemical reactor, distillation column, polymerization process, petroleum refinery units, are summarized. Finally, some concluding remarks and future considerations are made.
基金National Natural Foundation of China (No.60421002, No.70471052)
文摘Chemical process variables are always driven by random noise and disturbances. The closed-loop con-trol yields process measurements that are auto and cross correlated. The influence of auto and cross correlations on statistical process control (SPC) is investigated in detail by Monte Carlo experiments. It is revealed that in the sense of average performance, the false alarms rates (FAR) of principal component analysis (PCA), dynamic PCA are not affected by the time-series structures of process variables. Nevertheless, non-independent identical distribution will cause the actual FAR to deviate from its theoretic value apparently and result in unexpected consecutive false alarms for normal operating process. Dynamic PCA and ARMA-PCA are demonstrated to be inefficient to remove the influences of auto and cross correlations. Subspace identification-based PCA (SI-PCA) is proposed to improve the monitoring of dynamic processes. Through state space modeling, SI-PCA can remove the auto and cross corre-lations efficiently and avoid consecutive false alarms. Synthetic Monte Carlo experiments and the application in Tennessee Eastman challenge process illustrate the advantages of the proposed approach.
基金Supported by the National Natural Science Foundation of China(61374137,61490701,61174119)the State Key Laboratory of Integrated Automation of Process Industry Technology and Research Center of National Metallurgical Automation Fundamental Research Funds(2013ZCX02-03)
文摘Fault detection and identification are challenging tasks in chemical processes, the aim of which is to decide out of control samples and find fault sensors timely and effectively. This paper develops a partitioning principal component analysis(PPCA) method for process monitoring. A variable reasoning strategy is proposed and applied to recognize multiple fault variables. Compared with traditional process monitoring methods, the PPCA strategy not only reflects the local behavior of process variation in each model(each direction of principal components),but also improves the monitoring performance through the combination of local monitoring results. Then, a variable reasoning strategy is introduced to locate fault variables. Unlike the contribution plot, this method locates normal and fault variables effectively, and gives initiatory judgment for ambiguous variables. Finally, the effectiveness of the proposed process monitoring and fault variable identification schemes is verified through a numerical example and TE chemical process.
基金Supported by the 973 project of China (2013CB733600), the National Natural Science Foundation (21176073), the Doctoral Fund of Ministry of Education (20090074110005), the New Century Excellent Talents in University (NCET-09-0346), "Shu Guang" project (09SG29) and the Fundamental Research Funds for the Central Universities.
文摘The kernel principal component analysis (KPCA) method employs the first several kernel principal components (KPCs), which indicate the most variance information of normal observations for process monitoring, but may not reflect the fault information. In this study, sensitive kernel principal component analysis (SKPCA) is proposed to improve process monitoring performance, i.e., to deal with the discordance of T2 statistic and squared prediction error SVE statistic and reduce missed detection rates. T2 statistic can be used to measure the variation di rectly along each KPC and analyze the detection performance as well as capture the most useful information in a process. With the calculation of the change rate of T2 statistic along each KPC, SKPCA selects the sensitive kernel principal components for process monitoring. A simulated simple system and Tennessee Eastman process are employed to demonstrate the efficiency of SKPCA on online monitoring. The results indicate that the monitoring performance is improved significantly.
文摘Transporting hatching eggs from Hungary and incubating them abroad revealed lower hatchability compared to when the eggs were incubated in Hungary. Following transport, there were higher embryo losses and, notably, more malformed embryos. The aim of these initial trials was to determine if a testing device (crazy fit massage machine (CFM machine)) was able to replicate and model the mechanical impacts experienced during transport and reproduce the reduction in hatchability and increase the level of malformed embryos as observed in commercial practice. Tinytag~ high sensitivity shock and vibration loggers were used to monitor the impacts under field and trial conditions. Applying single 10 min treatments on the CFM machine, which used the same frequency (10-30 Hz) as the eggs experience under field conditions, induced the negative effect of transport, and lower hatching results were experienced. Three trials were conducted. Treated eggs in Trials 1 and 2 received automatically and periodical changing vibration in a range between 10-30 Hz for 10 min while in Trial 3 two different levels of impact were applied at 20 Hz and 30 Hz, respectively. Hatchability decreased due to the treatment significatly only in Trial 3. Significant differences were also detected in early dead levels in Trials 2 and 3 and the occurrences of malformation in Trials 1 and 3. All these results are in accordance with the field experience. Thus, the trials which examined the equipment were able to produce mechanical impacts that were repeatable in order to set up statistically reliable trials on hatching eggs.