The article delves into the development of a Non-Gaussian Process Monitoring Strategy for a Copper Cathode Manufacturing Unit (CCMU). The monitoring strategy being devised highlighted the issue of multi-stage process monitoring via the usage of Multi-block Independent Component Analysis (MBICA) techniques. MBICA is the multi-block variant of ICA technique which is prevalently used for process laden with non-Gaussian or non-normal data. Development of the monitoring strategy involved detection of fault(s) and their subsequent diagnosis. Detection of fault(s) was carried out by employment of I2 control chart whose control limit was established via Bootstrap procedure. The diagnosis of the detected fault was carried out by employment of fault diagnostic statistic. An amalgamation of MBICA and Multivariate Exponentially Weighted Moving Average (MEWMA) are also known as MBICA-MEWMA approach was also proposed for detection of incipient fault(s). The monitoring strategy thus developed was showcased for a CCMU which specialised in the manufacture of copper cathode which has got varied practical applications. The monitoring strategy thus devised was able to detect and diagnose the faults with appreciable accuracy.
The article delves into the development of Statistical Fault Detection and Diagnosis Strategies for an Integrated Steel Plant (ISP) taking into account the nonlinear relationship amongst the monitored Process and Feedstock Characteristics. The strategies being devised are based on Neural Network Fitting model cum Principal Component Analysis based technique (NNF-PCA) and Kernel Principal Component Analysis (KPCA) based technique. For detection of fault(s) Hotelling T2chart based on PCA and KPCA scores were employed. The article also proposes a 2-phase Fault Diagnosis approach christened as Preliminary Diagnosis phase and Specific Diagnosis phase. The Preliminary Diagnosis phase is based on Pattern Analysis of the control chart monitoring statistic observations and the Specific Diagnosis phase is based on the employment of appropriate Fault Diagnostic Statistic. The Preliminary Diagnosis reveals the broader source of assignable cause for the onset of the fault(s) and the Specific Diagnosis reveals the relative contribution of the individual Process and Feedstock characteristics. An in-depth comparative analysis between the NNF-PCA based strategy and KPCA based strategy w.r.t. three comparative aspects and four comparative parameters were carried out with their findings being duly highlighted which revealed the slight effectiveness of the KPCA based strategy with respect to the NNF-PCA based counterpart.
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