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DATA-DRIVEN
AND
MODEL-BASED
METHODS FOR
FAULT DETECTION
AND DIAGNOSIS
DATA-DRIVEN
AND
MODEL-BASED
METHODS FOR
FAULT DETECTION
AND DIAGNOSIS
MAJDI MANSOURI
MOHAMED-FAOUZI HARKAT
HAZEM N. NOUNOU
MOHAMED N. NOUNOU
Elsevier
Radarweg 29, PO Box 211, 1000 AE Amsterdam, Netherlands
The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, United Kingdom
50 Hampshire Street, 5th Floor, Cambridge, MA 02139, United States
Copyright © 2020 Elsevier Inc. All rights reserved.
No part of this publication may be reproduced or transmitted in any form or by any means,
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This book and the individual contributions contained in it are protected under copyright by the
Publisher (other than as may be noted herein).
Notices
Knowledge and best practice in this field are constantly changing. As new research and experience
broaden our understanding, changes in research methods, professional practices, or medical
treatment may become necessary.
Practitioners and researchers must always rely on their own experience and knowledge in
evaluating and using any information, methods, compounds, or experiments described herein. In
using such information or methods they should be mindful of their own safety and the safety of
others, including parties for whom they have a professional responsibility.
To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors,
assume any liability for any injury and/or damage to persons or property as a matter of products
liability, negligence or otherwise, or from any use or operation of any methods, products,
instructions, or ideas contained in the material herein.
ISBN: 978-0-12-819164-4
List of figures ix
List of tables xvii
About the authors xix
Acknowledgments xxi
List of acronyms xxiii
Nomenclature xxv
1. Introduction 1
References 6
v
vi Contents
Appendix 279
References 286
Index 289
List of figures
ix
x List of figures
Figure 3-4 The time evolution of the SPE (A), KGLRT (B) and
EWMA − KGLRT (C) statistics on a semi-logarithmic scale
in the presence of a single fault in T . 61
Figure 3-5 The time evolution of the SPE (A), KGLRT (B) and
EWMA − KGLRT (C) statistics on a semi-logarithmic scale
in the presence of simultaneous faults in CA and T . 62
Figure 3-6 KPLS diagram for nonlinear regression. 67
Figure 3-7 The time evolution of PLS-based Q statistic on a
semilogarithmic scale in the presence of a fault in CA . 69
Figure 3-8 The time evolution of KPLS-based Q statistic on a
semilogarithmic scale in the presence of a fault in CA . 70
Figure 3-9 The time evolution of PLS-based GLRT statistic on a
semilogarithmic scale in the presence of a fault in CA . 70
Figure 3-10 The time evolution of KPLS-based GLRT statistic on a
semilogarithmic scale in the presence of a fault in CA . 71
Figure 3-11 The time evolution of PLS-based Q statistic on a
semilogarithmic scale in the presence of a fault in T . 71
Figure 3-12 The time evolution of KPLS-based Q statistic on a
semilogarithmic scale in the presence of a fault in T . 71
Figure 3-13 The time evolution of PLS-based GLRT statistic on a
semilogarithmic scale in the presence of a fault in T . 72
Figure 3-14 The time evolution of KPLS-based GLRT statistic on a
semilogarithmic scale in the presence of a fault in T . 72
Figure 3-15 The time evolution of PLS-based Q statistic on a
semilogarithmic scale in the presence of simultaneous faults
in CA and T . 73
Figure 3-16 The time evolution of KPLS-based Q statistic on a
semilogarithmic scale in the presence of simultaneous faults
in CA and T . 73
Figure 3-17 The time evolution of PLS-based GLRT statistic on a
semilogarithmic scale in the presence of simultaneous faults
in CA and T . 74
Figure 3-18 The time evolution of KPLS-based GLRT statistic on a
semilogarithmic scale in the presence of simultaneous faults
in CA and T . 74
Figure 4-1 A schematic diagram of data representation at multiple
scales [1]. 81
Figure 4-2 Schematic illustration of MSPCA model. 83
Figure 4-3 Schematic illustration of proposed MSPCA-based MW-GLRT
algorithm. 86
List of figures xi
Figure 4-51 Monitoring faults (A) IDV17 , (B) IDV18 , (C) IDV19 , (D) IDV20 and
(E) IDV21 using SPE, KGLRT, and MS-KGLRT charts. 125
Figure 4-52 Representation of MSKPLS fault detection model. 126
Figure 4-53 The time evolution of the generated data X . 128
Figure 4-54 Time evolution of detection using PLS-based GLRT method. 128
Figure 4-55 Time evolution of detection using KPLS-based GLRT method. 129
Figure 4-56 Time evolution of detection using MSPLS-based GLRT method. 129
Figure 4-57 Time evolution of detection using MSKPLS-based GLRT
method. 130
Figure 4-58 Time evolution of detection using KPLS-based GLRT method. 131
Figure 4-59 Time evolution of detection using MSKPLS-based GLRT
method. 131
Figure 5-1 Time evolution of simulated interval-valued data. 150
Figure 5-2 Measurements and estimations of interval-valued data using
CIPCA model. 151
Figure 5-3 Time evolution of univariate interval GLR. 151
Figure 5-4 Time evolution of univariate interval weighted GLR. 152
Figure 5-5 Time evolution of multivariate GLR. 152
Figure 5-6 Time evolution of multivariate interval weighted GLR. 152
Figure 5-7 Distillation column interval-valued measurements. 153
Figure 5-8 Evolution of the VIRE with respect to the number of principal
components . 154
Figure 5-9 Measurements and estimations. 154
Figure 5-10 Time evolution of univariate interval GLR. 155
Figure 5-11 Time evolution of univariate interval weighted GLR. 155
Figure 5-12 Time evolution of multivariate interval GLR. 155
Figure 5-13 Time evolution of multivariate interval weighted GLR. 156
Figure 5-14 Ozone concentrations for single-valued and interval-valued
data. 157
Figure 5-15 Evolution of VIRE with respect to the number of principal
components. 157
Figure 5-16 Measurements and estimations of O3 station 1. 158
Figure 5-17 Measurements and estimations of O3 station 3. 158
Figure 5-18 Time evolution of univariate interval GLR with a fault on x7 . 159
Figure 5-19 Time evolution of univariate interval weighted GLR with a
fault on x7 . 159
Figure 5-20 Time evolution of multivariate interval GLR with a fault on x7 . 159
Figure 5-21 Time evolution of multivariate interval weighted GLR with a
fault on x7 . 160
Figure 5-22 Time evolution of simulated data. 163
xiv List of figures
Figure 5-23 The time evolution of the MRPCA-based SPE statistic in the
presence of faults in x2 and x3 . 165
Figure 5-24 The time evolution of the MRPCA-based EWMA statistic in the
presence of faults in x2 and x3 . 165
Figure 5-25 The time evolution of the MRPCA-based GLRT statistic in the
presence of faults in x2 and x3 . 166
Figure 5-26 The time evolution of the MRPCA-based EWMA statistic in the
presence of faults in x2 and x3 . 166
Figure 5-27 Measurements and estimations of O3 station 1. 167
Figure 5-28 Measurements and estimations of O3 station 3. 167
Figure 5-29 The time evolution of the MRPCA-based SPE statistic in the
presence of faults in O3 . 168
Figure 5-30 The time evolution of the MRPCA-based EWMA statistic in the
presence of faults in x2 and x3 . 168
Figure 5-31 The time evolution of the MRPCA-based GLRT statistic in the
presence of faults in O3 . 169
Figure 5-32 The time evolution of the MRPCA-based EWMA statistic in the
presence of faults in O3 . 169
Figure 5-33 Time evolution of interval-valued simulated variables. 177
Figure 5-34 Scatter plots of predicted and observed training data y1 . 177
Figure 5-35 Scatter plots of predicted and observed training data y2 . 178
Figure 5-36 Evolution of Q1,x in both fault-free and faulty cases. 178
Figure 5-37 Evolution of Q1,y in both fault-free and faulty cases. 179
Figure 5-38 Evolution of Q2,x in both fault-free and faulty cases. 179
Figure 5-39 Evolution of Q2,y in both fault-free and faulty cases. 180
Figure 5-40 Evolution of Q3,x in both fault-free and faulty cases. 180
Figure 5-41 Evolution of Q3,y in both fault-free and faulty cases. 181
Figure 5-42 Evolution of Q4,x in both fault-free and faulty cases. 181
Figure 5-43 Evolution of Q4,y in both fault-free and faulty cases. 182
Figure 5-44 Evolution of I Gx in both fault-free and faulty cases. 182
Figure 5-45 Evolution of I Gy in both fault-free and faulty cases. 183
Figure 5-46 Distillation column interval-valued measurements. 184
Figure 5-47 Evolution of Q1,x and Q1,y with a fault on variable x2 . 184
Figure 5-48 Evolution of Q2,x and Q2,y with a fault on variable x2 . 185
Figure 5-49 Evolution of Q3,x and Q3,y with a fault on variable x2 . 185
Figure 5-50 Evolution of Q4,x and Q4,y with a fault on variable x2 . 186
Figure 5-51 Evolution of IGLRx and IGLRy with a fault on variable x2 . 186
Figure 5-52 Evolution of Q4,x and Q4,y with a fault on variable y2 . 187
Figure 5-53 Evolution of IGLRx and IGLRy with a fault on variable y2 . 188
Figure 5-54 3-D scatter plot of the generated interval-valued data. 199
List of figures xv
Figure 5-55 Time evolution of indices T 2 and SPE in KPCA model with a
fault on variable x1 . 200
Figure 5-56 Time evolution of indices T 2 and SPE in IKPCACR model
with a fault on variable x2 . 200
Figure 5-57 Time evolution of x3 . 201
Figure 5-58 Time evolution of indices T 2 and SPE in KPCA model with
IDV-1 fault. 202
Figure 5-59 Time evolution of indices T 2 and SPE in IKPCA model with
IDV-1 fault. 203
Figure 5-60 Time evolution of indices T 2 and SPE in IKPCA model with
IDV-1 fault. 203
Figure 5-61 Time evolution of indices IGLRTUL in IKPCA model with IDV-1
fault. 204
Figure 5-62 Time evolution of indices IGLRTCR in IKPCA model with IDV-1
fault. 204
Figure 5-63 Time evolution of univariate GLRT index based on IKPLSUL
model. 211
Figure 5-64 Time evolution of multivariate GLRT index based on IKPLSUL
model. 211
Figure 5-65 Time evolution of univariate GLRT index based IKPLSCR model. 213
Figure 5-66 Time evolution of multivariate GLRT index based on IKPLSCR
model. 213
Figure 6-1 Plots of samples of normal and faulty signals. 222
Figure 6-2 General flow-chart of the multiobjective optimization process. 232
Figure 6-3 Multiscale EWMA strategy. 233
Figure 6-4 PF-based MS-EWMA fault detection strategy. 234
Figure 6-5 State estimation of the variables (A) XDCO , (B) SO and (C)
XBH using UKF and PF. 236
Figure 6-6 State estimation of the variables (A) SNH , (B) SNO and (C)
XBA using UKF and PF. 237
Figure 6-7 Monitoring a bias fault in SO using (A) Shewhart, (B) EWMA,
and (C) MS-EWMA methods. 239
Figure 6-8 Monitoring a drift fault in SO using (A) Shewhart, (B) EWMA,
and (C) MS-EWMA methods. 241
Figure 6-9 Monitoring a fault in X using (A) EWMA, (B) SS-DEWMA, and
(C) OWSS-DEWMA charts. 247
Figure 6-10 Qualitative model of the CSEC (simplified). 248
Figure 6-11 Estimation of state variables using various state estimation
techniques. 249
Figure 6-12 Monitoring a multiple faults in cadaverine Cadav using (A)
EWMA, (B) SS-DEWMA and (C) OWSS-DEWMA charts. 251
xvi List of figures
Figure 6-13 Monitoring a fault in Cadav using (A) EWMA, (B) SS-DEWMA
and (C) OWSS-DEWMA charts. 253
Figure 6-14 Monitoring a multiple faults in Cadav and Lys using (A)
EWMA, (B) SS-DEWMA and (C) OWSS-DEWMA charts. 254
Figure 1 Tennessee Eastman process. 279
Figure 2 Basic distillation column controlled with LV-configuration. 283
Figure 3 Ozone concentrations for the first three stations. 285
Figure 4 Ozone concentrations for the first station, single-valued and
interval-valued representations. 285
List of tables
xvii
xviii List of tables
xxi
List of acronyms
xxiii
Nomenclature
Latin letters
X ∈ RN ×m Input data matrix
x ∈ Rm Input vector
y ∈ Rp Output vector
t ∈ R Latent variable
P∈R Eigenvector matrix
p Eigenvector
I Identity matrix
E Residual matrix
e Residual vector
m Number of inputs
n Number of samples
Number of retained principal components
T2 Hotelling statistic
Q Squared prediction error statistic
T Generalized likelihood ratio test statistic
w Window length
Greek letters
Eigenvalue matrix
Model error
λ Eigenvalue
σ Standard deviation
φ(·) Nonlinear mapping
ψ Wavelet basis function
φ Orthonormal scaling function
xxv
CHAPTER 1
Introduction
Process monitoring is essential for proper and safe operation of various
industrial processes (like chemical and environmental processes), and it has
recently become even more important than ever before.
Proper operation of complex chemical processes, such as those in the oil
and gas industries, requires careful monitoring of certain key process vari-
ables to enhance the productivity of these processes and, more importantly,
to avoid disasters in the cases of failure [1]. Many serious accidents have
occurred in the past few decades in various chemical and petrochemical
plants all over the world. These accidents include the Union Carbide ac-
cident [2,3], the Piper Alpha accident [4,5], and the Al-Ahmedi (Kuwait)
accident [6]. The Union Carbide accident occurred in Bhopal, India, in
1984, where a major toxic gas leak resulted in over 3000 fatalities and in-
jured 400,000 others in the surrounding neighborhoods [2,3]. The 1988
accident in Piper Alpha (an oil production plant operated by Occidental
Chemical in the North Sea) involved an explosion killing 167 men, leaving
only 61 survivors [4,5]. The accident in Mina Al-Ahmedi in 2000, on the
other hand, was due to a failure in a condensate line in a refinery plant caus-
ing the death of 5 people and injuring 50 others [6]. These accidents show
that tight monitoring of chemical and petrochemical processes is essential
for safe and profitable operation of these plants.
Also, monitoring the atmospheric air pollution levels is extremely im-
portant for the safety of humans and the marine life, especially in areas with
large fuel productions or consumptions and large climate fluctuations [7].
For example, the heat wave in France in the summer of 2003 was linked to
an exceptional ozone pollution that affected the entire European commu-
nity [8]. The consequences of this heat wave demonstrated the importance
of having reliable warning systems to detect unexpected pollution levels
and any unforeseeable events [8]. Proper monitoring of air pollutants pro-
vides useful information that can help people take the needed precautions
to avoid undesirable consequences. During the past few decades, a lot of
effort has been made to improve air quality.
Fault detection is often used for process monitoring. Possible faults can
be due to malfunctioning sensor/s (called sensor faults) or to abnormal
changes in the process. Sensor faults are usually quantified by sudden (or
Data-Driven and Model-Based Methods for Fault Detection and Diagnosis Copyright © 2020 Elsevier Inc.
https://doi.org/10.1016/B978-0-12-819164-4.00010-8 All rights reserved. 1
2 Data-Driven and Model-Based Methods for Fault Detection and Diagnosis
P(z|y) ∝ P(y|z)P(z),
where P(y|z) is the conditional distribution of the data given the model
parameter vector z, which is called the likelihood function, and P(z) is
the prior distribution, which quantifies our belief about z before obtain-
ing the measurement. Thus the Bayes rule specifies how our prior belief,
quantified by the priori distribution, is updated according to the mea-
sured data y. Unfortunately, for most nonlinear systems and non-Gaussian
noise observations, a closed-form analytic expression of the posterior dis-
tribution of the state is untractable [37]. To overcome this drawback, a
nonparametric Monte Carlo sampling-based method called the sequen-
tial Monte Carlo method (SMC) (also known as particle filtering (PF))
4 Data-Driven and Model-Based Methods for Fault Detection and Diagnosis
To deal with scenarios where the process model is available and has
a pre-defined structure (obtained using material and energy balances), an
improved model-based fault detection technique that aims at enhancing the
monitoring of industrial systems is developed. The objectives are twofold.
Firstly, a state estimation technique that can accurately estimate the state
variables in such systems will be developed; secondly, new fault detection
charts based on exponentially weighted moving average (EWMA) will be
proposed.
Finally, the developed fault detection methods are applied to enhance
monitoring various chemical, biological, and environmental processes.
This scientific synthesis is organized in seven chapters. Chapter 2
presents detailed descriptions of the developed linear LVR-based gener-
alized likelihood ratio test (GLRT) methods for fault detection. Chapter 3
extends the linear LVR-based GLRT approaches to deal with nonlinearities
on the systems by developing nonlinear LVR (including kernel PCA and
kernel PLS) based GLRT fault detection techniques. In Chapter 4, multi-
scale LVR-based fault detection approaches are presented, which improve
the monitoring abilities of the classical LV-based techniques. Chapter 5
presents interval LVR-based approaches for monitoring uncertain systems,
followed by their applications to chemical and environmental processes.
Then, in Chapter 6 the model-driven fault detection techniques based on
particle filter (PF) and exponentially weighted moving average (EWMA)
and their applications to monitoring biological processes are presented. Fi-
nally, a summary of the main conclusions out of this report and the future
works are presented in Chapter 7.
References
[1] F. Khan, S. Abbasi, Major accidents in process industries and an analysis of causes
and consequences, Journal of Loss Prevention in the Process Industries 12 (5) (1999)
361–378.
[2] V. Dhara, The Union Carbide disaster in Bhopal: a review of health effects, Archives
of Environmental Health 27 (5) (2002) 391–404.
[3] B. Bowonder, The Bhopal accident, Technological Forecasting and Social Change
32 (2) (1987) 169–182.
[4] L. Cullen, The Public Inquiry into the Piper Alpha Disaster, HMSO, 1990.
[5] M. Pate-Cornell, Learning from the Piper Alpha accident: a postmortem analysis of
technical and organizational factors, Risk Analysis 13 (2) (1993) 215–232.
[6] V. Venkatasubramanian, R. Rengaswamy, S. Kavuri, K. Yin, A review of process fault
detection and diagnosis part I: quantitative model-based methods, Computers and
Chemical Engineering 27 (2003) 293–311.
Introduction 7