Overmany alarms of modern chemical process give the operators many difficulties to decision and diag- nosis. In order to ensure safe production and process operating, management and optimization of alarm information a...Overmany alarms of modern chemical process give the operators many difficulties to decision and diag- nosis. In order to ensure safe production and process operating, management and optimization of alarm information are challenge work that must be confronted. A new process alarm management method based on fuzzy clustering- ranking algorithm is proposed. The fuzzy clustering algorithm is used to cluster rationally the process variables, and difference driving decision algorithm ranks different clusters and process parameters in every cluster. The alarm signal of higher rank is handled preferentially to manage effectively alarms and avoid blind operation. The validity of proposed algorithm and solution is verified by the practical application of ethylene cracking furnace system. It is an effective and dependable alarm management method to improve operating safety in industrial process.展开更多
To alleviate the heavy load of massive alarm on operators, alarm threshold in chemical processes was optimized with principal component analysis(PCA) weight and Johnson transformation in this paper. First, few variabl...To alleviate the heavy load of massive alarm on operators, alarm threshold in chemical processes was optimized with principal component analysis(PCA) weight and Johnson transformation in this paper. First, few variables that have high PCA weight factors are chosen as key variables. Given a total alarm frequency to these variables initially, the allowed alarm number for each variable is determined according to their sampling time and weight factors. Their alarm threshold and then control limit percentage are determined successively. The control limit percentage of non-key variables is determined with 3σ method alternatively. Second, raw data are transformed into normal distribution data with Johnson function for all variables before updating their alarm thresholds via inverse transformation of obtained control limit percentage. Alarm thresholds are optimized by iterating this process until the calculated alarm frequency reaches standard level(normally one alarm per minute). Finally,variables and their alarm thresholds are visualized in parallel coordinate to depict their variation trends concisely and clearly. Case studies on a simulated industrial atmospheric-vacuum crude distillation demonstrate that the proposed alarm threshold optimization strategy can effectively reduce false alarm rate in chemical processes.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
基金Partially supported by the National Natural Science Foundation of China (No. 29976003), the Key Research Project ofScience and Technology from Ministry of Education in China (No. 01024), and Sinopec Science & Technology DevelopmentProject (No. E03007)
文摘Overmany alarms of modern chemical process give the operators many difficulties to decision and diag- nosis. In order to ensure safe production and process operating, management and optimization of alarm information are challenge work that must be confronted. A new process alarm management method based on fuzzy clustering- ranking algorithm is proposed. The fuzzy clustering algorithm is used to cluster rationally the process variables, and difference driving decision algorithm ranks different clusters and process parameters in every cluster. The alarm signal of higher rank is handled preferentially to manage effectively alarms and avoid blind operation. The validity of proposed algorithm and solution is verified by the practical application of ethylene cracking furnace system. It is an effective and dependable alarm management method to improve operating safety in industrial process.
基金Supported by the National Natural Science Foundation of China(21576143)
文摘To alleviate the heavy load of massive alarm on operators, alarm threshold in chemical processes was optimized with principal component analysis(PCA) weight and Johnson transformation in this paper. First, few variables that have high PCA weight factors are chosen as key variables. Given a total alarm frequency to these variables initially, the allowed alarm number for each variable is determined according to their sampling time and weight factors. Their alarm threshold and then control limit percentage are determined successively. The control limit percentage of non-key variables is determined with 3σ method alternatively. Second, raw data are transformed into normal distribution data with Johnson function for all variables before updating their alarm thresholds via inverse transformation of obtained control limit percentage. Alarm thresholds are optimized by iterating this process until the calculated alarm frequency reaches standard level(normally one alarm per minute). Finally,variables and their alarm thresholds are visualized in parallel coordinate to depict their variation trends concisely and clearly. Case studies on a simulated industrial atmospheric-vacuum crude distillation demonstrate that the proposed alarm threshold optimization strategy can effectively reduce false alarm rate in chemical processes.
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.
