Robust Fault Detection in Monitoring Chemical Processes Using Multi-Scale PCA with KD Approach

Abstract

Effective fault detection in chemical processes is of utmost importance to ensure operational safety, minimize environmental impact, and optimize production efficiency. To enhance the monitoring of chemical processes under noisy conditions, an innovative statistical approach has been introduced in this study. The proposed approach, called Multiscale Principal Component Analysis (PCA), combines the dimensionality reduction capabilities of PCA with the noise reduction capabilities of wavelet-based filtering. The integrated approach focuses on extracting features from the multiscale representation, balancing the need to retain important process information while minimizing the impact of noise. For fault detection, the Kantorovich distance (KD)-driven monitoring scheme is employed based on features extracted from Multiscale PCA to efficiently detect anomalies in multivariate data. Moreover, a nonparametric decision threshold is employed through kernel density estimation to enhance the flexibility of the proposed approach. The detection performance of the proposed approach is investigated using data collected from distillation columns and continuously stirred tank reactors (CSTRs) under various noisy conditions. Different types of faults, including bias, intermittent, and drift faults, are considered. The results reveal the superior performance of the proposed multiscale PCA-KD based approach compared to conventional PCA and multiscale PCA-based monitoring methods.