Fault monitoring using novel adaptive kernel principal component analysis integrating grey relational analysis

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The kernel principal component analysis (KPCA) is widely used as a fault monitoring tool for complex nonlinear chemical processes in recent years. The cumulative contribution rate that extracts the kernel principal is usually obtained relied on a fixed model, which cannot be employed for time-varying chemical processes. Hence, a novel adaptive kernel principal component analysis (AKPCA) integrating grey relational analysis (GRA) (AKPCA-GRA) is proposed to dynamically monitor the fault occurrence. A moving window integrating the threshold method is used to adaptively extract the kernel principal for chemical processes. Then the corresponding T2 and Q statistics calculated by the selected kernel principal based on the AKPCA decides whether the fault has occurred. Moreover, the GRA method is used to analyze and calculate the correlation coefficient of abnormal features obtained based on the APKCA method, which provides the operational guidance for the nonlinear chemical process to find out the variable causing the fault. Finally, the proposed method is verified using the Tennessee Eastman (TE) process. The case results demonstrate that the proposed method outperforms the KPCA, the KPCA based on the threshold and the moving window principal component analysis, the support vector machine (SVM) and the Logistic Regression (LR) in terms of the missed alarm rate (MAR) and the false alarm rate (FAR), which can effectively analyze the variables causing the fault.