This paper develops a methodology to combine diagnostic information from various fault detection and isolation tools to diagnose the true root cause of an abnormal event in industrial processes. Limited diagnostic information from kernel principal component analysis, other online fault detection and diagnostic tools, and process knowledge were combined through Bayesian belief network. The proposed methodology will enable an operator to diagnose the root cause of the abnormality. Further, some challenges on application of Bayesian network on process fault diagnosis such as network connection determination, estimation of conditional probabilities, and cyclic loop handling were addressed. The proposed methodology was applied to Fluid Catalytic Cracking unit and Tennessee Eastman Chemical Process. In both cases, the proposed approach showed a good capability of diagnosing the root cause of abnormal conditions.
Kernel principal component analysis (KPCA) based monitoring has good fault detection capability for nonlinear process systems; however, it can only isolate variables that have a contribution to the occurrence of a fault, and thus it is not precise in diagnosing. Since there is a cause and effect relationship between different variables in a process, accordingly a network‐based causality analysis method was developed for different fault scenarios to show causal relationships between different variables and to see the causal effect between the variables most contributing to the occurrence of a fault. It was shown that KPCA in combination with causality analysis is a powerful tool for diagnosing the root cause of a fault in the process. In this paper the proposed methodology was applied to a fluid catalytic cracking (FCC) unit and the Tennessee Eastman process to diagnose root causes for different faulty scenarios.
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