Skip to main content
Log in

Fault diagnosis and process monitoring using a statistical pattern framework based on a self-organizing map

  • Published:
Journal of Central South University Aims and scope Submit manuscript

Abstract

A multivariate method for fault diagnosis and process monitoring is proposed. This technique is based on a statistical pattern (SP) framework integrated with a self-organizing map (SOM). An SP-based SOM is used as a classifier to distinguish various states on the output map, which can visually monitor abnormal states. A case study of the Tennessee Eastman (TE) process is presented to demonstrate the fault diagnosis and process monitoring performance of the proposed method. Results show that the SP-based SOM method is a visual tool for real-time monitoring and fault diagnosis that can be used in complex chemical processes. Compared with other SOM-based methods, the proposed method can more efficiently monitor and diagnose faults.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Similar content being viewed by others

References

  1. CHIANG L H, BRAATZ R D, RUSSELL E L. Fault detection and diagnosis in industrial systems [M]. Berlin, Germany: Springer, 2001.

    Book  Google Scholar 

  2. GE Zhi-qiang, SONG Zhi-huan. Multivariate statistical process control: Process monitoring methods and applications [M]. Berlin, Germany: Springer, 2013.

    Book  Google Scholar 

  3. CHIANG L H, RUSSELL E L, BRAATZ R D. Fault diagnosis in chemical processes using Fisher discriminant analysis, discriminant partial least squares, and principal component analysis [J]. Chemometrics and intelligent laboratory systems, 2000, 50(2): 243–252.

    Article  Google Scholar 

  4. JIANG Qing-chao, YAN Xue-feng. Statistical monitoring of chemical processes based on sensitive kernel principal components [J]. Chinese Journal of Chemical Engineering, 2013, 21(6): 633–643.

    Article  Google Scholar 

  5. ODIOWEI P E P, CAO Yi. Nonlinear dynamic process monitoring using canonical variate analysis and kernel density estimations [J]. IEEE Transactions on Industrial Informatics, 2010, 6(1): 36–45.

    Article  Google Scholar 

  6. KANO M, HASEBE S, HASHIMOTO I, OHNO H. Statistical process monitoring based on dissimilarity of process data [J]. AIChE Journal, 2002, 48(6): 1231–1240.

    Article  Google Scholar 

  7. YELAMOS I, ESCUDERO G, GRAELLS M, PUIGJANER L. Performance assessment of a novel fault diagnosis system based on support vector machines [J]. Computers & Chemical Engineering, 2009, 33(1): 244–255.

    Article  Google Scholar 

  8. YU J, QIN S J. Multimode process monitoring with Bayesian inference-based finite Gaussian mixture models [J]. AIChE Journal, 2008, 54(7): 1811–1829.

    Article  Google Scholar 

  9. YU Jian-bo. Hidden Markov models combining local and global information for nonlinear and multimodal process monitoring [J]. Journal of Process Control, 2010, 20(3): 344–359.

    Article  Google Scholar 

  10. WANG Cun-jie, ZHAO Yu-hong. A new fault detection method based on artificial immune systems [J]. Asia-Pacific Journal of Chemical Engineering, 2008, 3(6): 706–711.

    Article  Google Scholar 

  11. ZHAO Jin-song, SHU Yi-dan, ZHU Jian-feng, DAI Yi-yang. An online fault diagnosis strategy for full operating cycles of chemical processes [J]. Industrial & Engineering Chemistry Research, 2014, 53(13): 5015–5027.

    Article  Google Scholar 

  12. HE Q P, WANG J. Statistics pattern analysis: A new process monitoring framework and its application to semiconductor batch processes [J]. AIChE Journal, 2011, 57(1): 107–121.

    Article  Google Scholar 

  13. WANG J, HE Q P. Multivariate statistical process monitoring based on statistics pattern analysis [J]. Industrial & Engineering Chemistry Research, 2010, 49(17): 7858–7869.

    Article  Google Scholar 

  14. GALICIA H J, HE Q P, WANG J. A comprehensive evaluation of statistics pattern analysis based process monitoring [C]// International Symposium on Advanced Control of Chemical Processes, Furama Riverfront, Singapore: ADCHEM. 2012: 39–44.

    Google Scholar 

  15. CHEN Xin-yi, YAN Xue-feng. Fault diagnosis in chemical process based on self-organizing map integrated with fisher discriminant analysis [J]. Chinese Journal of Chemical Engineering, 2013, 21(4): 382–387.

    Article  Google Scholar 

  16. WU Si-tao, CHOW T W S. Induction machine fault detection using SOM-based RBF neural networks [J]. IEEE Transactions on Industrial Electronics, 2004, 51(1): 183–194.

    Article  Google Scholar 

  17. SIROLA M, TALONEN J, LAMPI G. SOM based methods in early fault detection of nuclear industry [C]// 17th European Symposium on Artificial Neural Networks, Burge, Belgium: ESANN, 2009.

    Google Scholar 

  18. ZHONG Fei, SHI Tie-lin, HE Tao. Fault diagnosis of motor bearing using self-organizing maps [C]// Electrical Machines and Systems, 2005. ICEMS 2005. Proceedings of the Eighth International Conference on. Nanjing: IEEE, 2005: 2411–2414.

    Google Scholar 

  19. CHEN Xin-yi, YAN Xue-feng. Using improved self-organizing map for fault diagnosis in chemical industry process [J]. Chemical Engineering Research and Design, 2012, 90(12): 2262–2277.

    Article  Google Scholar 

  20. KOHONEN T. Self-organizing maps [M]. Germany: Springer, 2001.

    Book  Google Scholar 

  21. ULTSCH A. U*-matrix: A tool to visualize clusters in high dimensional data [M]. Berlin: Fachbereich Mathematik und Informatik, 2003.

    Google Scholar 

  22. NG Y S, SRINIVASAN R. Multivariate temporal data analysis using self-organizing maps. 2. Monitoring and diagnosis of multistate operations [J]. Industrial & Engineering Chemistry Research, 2008, 47(20): 7758–7771.

    Article  Google Scholar 

  23. DOWMS J J, VOGEL E F. A plant-wide industrial process control problem [J]. Computers & Chemical Engineering, 1993, 17(3): 245–255.

    Article  Google Scholar 

  24. LYMAN P R, GEORGAKIS C. Plant-wide control of the Tennessee Eastman problem [J]. Computers & Chemical Engineering, 1995, 19(3): 321–331.

    Article  Google Scholar 

  25. ZHU Zhi-bo, SONG Zhi-huan, PALAZOGLU A. Transition process modeling and monitoring based on dynamic ensemble clustering and multiclass support vector data description [J]. Industrial & Engineering Chemistry Research, 2011, 50(24): 13969–13983.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Xue-feng Yan  (颜学峰).

Additional information

Foundation item: Project(2013CB733605) supported by the National Basic Research Program of China; Project(21176073) supported by the National Natural Science Foundation of China; Project supported by the Fundamental Research Funds for the Central Universities, China

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Song, Y., Jiang, Qc. & Yan, Xf. Fault diagnosis and process monitoring using a statistical pattern framework based on a self-organizing map. J. Cent. South Univ. 22, 601–609 (2015). https://doi.org/10.1007/s11771-015-2561-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11771-015-2561-3

Key words

Navigation