ChangKyoo Yoo

Fault detection of batch processes using multiway kernel principal component analysis

Batch processes are very important in most industries and are used to produce high-quality materials, which causes their monitoring and control to emerge as essential techniques. Several multivariate statistical analyses, including multiway principal component analysis (MPCA), have been developed for the monitoring and fault detection of batch process. In this paper, a new batch monitoring method using multiway kernel principal component analysis (MKPCA) is proposed. Three-way batch data of normal batch process are unfolded batch-wise, and then KPCA is used to capture the nonlinear characteristics within normal batch processes. The proposed monitoring method was applied to fault detection in the simulation benchmark of fed-batch penicillin production. In both off-line analysis and on-line batch monitoring, the proposed approach can effectively capture the nonlinear relationships among process variables. In on-line monitoring, MKPCA can detect significant deviation which may cause a lower quality of final products. MPCA, however, has a limit to detect faults.

Nonlinear modeling and adaptive monitoring with fuzzy and multivariate statistical methods in biological wastewater treatment plants.

A new approach to nonlinear modeling and adaptive monitoring using fuzzy principal component regression (FPCR) is proposed and then applied to a real wastewater treatment plant (WWTP) data set. First, principal component analysis (PCA) is used to reduce the dimensionality of data and to remove collinearity. Second, the adaptive credibilistic fuzzy-c-means method is used to appropriately monitor diverse operating conditions based on the PCA score values. Then a new adaptive discrimination monitoring method is proposed to distinguish between a large process change and a simple fault. Third, a FPCR method is proposed, where the Takagi-Sugeno-Kang (TSK) fuzzy model is employed to model the relation between the PCA score values and the target output to avoid the over-fitting problem with original variables. Here, the rule bases, the centers and the widths of TSK fuzzy model are found by heuristic methods. The proposed FPCR method is applied to predict the output variable, the reduction of chemical oxygen demand in the full-scale WWTP. The result shows that it has the ability to model the nonlinear process and multiple operating conditions and is able to identify various operating regions and discriminate between a sustained fault and a simple fault (or abnormalities) occurring within the process data.

On-line batch process monitoring using a consecutively updated multiway principal component analysis model

Batch processes lie at the heart of many industries; hence the effective monitoring and control of batch processes is crucial to the production of high-quality materials. Multiway principal component analysis (MPCA) has been widely used for batch monitoring and has proved to be an effective method for monitoring many industrial batch processes. However, because MPCA is a fixed-model monitoring technique, it gives false alarms when it is used to monitor real processes whose normal operation involves slow changes. In this paper, we propose a simple on-line batch monitoring method that uses a consecutively updated MPCA model. The key to the proposed approach is that whenever a batch successfully remains within the bounds of normal operation, its batch data are added to the historical database of normal data and a new MPCA model is developed based on the revised database. The proposed method was applied to monitoring fed-batch penicillin production, and the results were compared with those obtained using conventional MPCA. The simulation results clearly show that the ability of the proposed method to adapt to new normal operating conditions eliminates the many false alarms generated by the fixed model and provides a reliable monitoring chart.

Application of fuzzy partial least squares (FPLS) modeling nonlinear biological processes

We applied a nonlinear fuzzy partial least squares (FPLS) algorithm for modeling a biological wastewater treatment plant. FPLS embeds the Takagi-Sugeno-Kang (TSK) fuzzy model into the regression framework of the partial least squares (PLS) method, in which FPLS utilizes a TSK fuzzy model for nonlinear characteristics of the PLS inner regression. Using this approach, the interpretability of the TSK fuzzy model overcomes some of the handicaps of previous nonlinear PLS (NLPLS) algorithms. As a result, the FPLS model gives a more favorable modeling environment in which the knowledge of experts can be easily applied. Results from applications show that FPLS has the ability to model the nonlinear process and multiple operating conditions and is able to identify various operating regions in a simulation benchmark of biological process as well as in a full-scale wastewater treatment process. The result shows that it has the ability to model the nonlinear process and handle multiple operating conditions and is able to predict the key components of nonlinear biological processes.

Sensor validation and reconciliation for a partial nitrification process

Wastewater treatment plants (WWTP) are notorious for poor data quality and sensor reliability due to the hostile environment in which the measurement equipment has to function. In this paper, a structured residual approach with maximum sensitivity (SRAMS) based on the redundancy of the measurements is used to detect, identify and reconstruct single and multiple sensor faults in a single reactor for high activity ammonia removal over nitrite (SHARON) process. SRAMS is based on inferences, which are insensitive to the faults in the sensor of interest and sensitive to faults in the other sensors. It is used for four types of sensor failure detection: bias, drift, complete failure and precision degradation. The application of sensor validation shows that single and multiple sensor faults can be detected and that the fault magnitude and fault type can be estimated by the reconstruction scheme. This sensor validation method is not limited by the type or application of the considered sensors. The methodology can thus easily be applied for sensor surveillance of other continuously measuring sensors and analysers.

Soft sensor and adaptive model-based dissolved oxygen control for biological wastewater treatment processes

In wastewater treatment processes (WWTP), the respiration rate (R) and oxygen transfer rate (KLa) are two of the most important variables for monitoring biological activity and assessing process co...

Nonlinear model-based dissolved oxygen control in a biological wastewater treatment process

The dissolved oxygen (DO) concentration has been an important process parameter in the biological wastewater treatment process (WWTP). In this paper, we propose a nonlinear control scheme to maintain the dissolved oxygen level of an activated sludge system. Without any linearization or model reduction, it can directly incorporate the nonlinear DO process model with on-line estimation of the respiration rate (R) and the oxygen transfer rate (KLa). Simulation results show that it outperforms a control performance of the PID controller. Since it incorporates the process disturbance and nonlinearity in the controller design, the suggested method can efficiently deal with the operating condition changes that occur frequently in the wastewater treatment process.

Multivariate Statistical Monitoring of Nonlinear Biological Processes Using Kernel PCA

Abstract In this paper, a new nonlinear process monitoring technique based upon kernel principal component analysis (KPCA) is developed. In recent years, KPCA has been emerging to tackle the nonlinear monitoring problem. KPCA can efficiently compute principal components in high dimensional feature spaces by the use of integral operator and nonlinear kernel functions. The basic idea of KPCA is to first map the input space into a feature space via nonlinear mapping and then compute the principal components in that feature space. In comparison to other nonlinear PCA techniques, KPCA requires only the solution of an eigenvalue problem without any nonlinear optimization. Based on T2 and SPE charts in the feature space, KPCA was applied to fault detection in the simulation benchmark of the biological wastewater treatment process (WWTP). The proposed approach can effectively capture the nonlinear relationship in process variables and its application for process monitoring shows better performance than PCA

Process monitoring of continuous processes with periodic operation patterns

Application of conventional statistical monitoring methods to periodic processes can result in frequent false alarms and/or missed faults due to their common non-stationary behavior seen over a period. To address this, we propose to identify and use a stochastic statespace model that describes statistical behavior of the changes occurring from period to period. This model, when retooled as a periodically time-varying model, can be used for on-line monitoring and estimation with the aid of a Kalman filter. The same model can also be used for inferential estimation of the variables that ere difficult or slow to measure on-line. The proposed approach is applied to a simulation benchmark of waste-water treatment process, which exhibit strong diurnal changes in the feed stream, and compared against the Principal Component Analysis (PCA) and and Partial Least Squares (PLS) methods.

On-line dynamic monitoring of the SHARON process for sustainable nitrogen removal from wastewater

Abstract The goal of this work is the development of a suitable monitoring module, which is to be the first module of an integrated fault detection and control system for the SHARON process. To model the process properly, different PCA models are tested. As a first step, PCA is used in an iterative manner to exclude data not considered to represent normal operational conditions and process behaviour from the original data set. To improve the performance of the identified model, it is decided to account for dynamics in the SHARON process by means of auto-regressive exogenous (ARX) structuring of data before the identification. A fruitful replacement of missing values for this purpose is done by means of a static PCA model. It is shown that the different criteria used in model selection lead to the same DPCA model. In this paper all steps of the monitoring module design are explained and the performance of different models is analyzed.