Multivariate statistical process monitoring

Demands regarding production efficiency, product quality, safety levels and environment protection are continuously increasing in the process industry. The way to accomplish these demands is to introduce the more complex automatic control systems which require more process variables to be measured and more advanced measurement systems. Quality and reliable measurements of process variables are the basis for the quality process control. Process equipment failures can significantly deteriorate production process and even cause production outage, resulting in high additional costs. This paper analyzes automatic fault detection and identification of process measurement equipment, i.e. sensors. Different statistical methods can be used for this purpose in a way that continuously acquired measurements are analyzed by these methods. In this paper, PCA and ICA methods are used for relationship modelling which exists between process variables while Hotelling's (T2), I2 and Q (SPE) statistics are used for fault detection because they provide an indication of unusual variability within and outside normal process workspace. Contribution plots are used for fault identification. The algorithms for the statistical process monitoring based on PCA and ICA methods are derived and applied to the two processes of different complexity. Apart from that, their fault detection ability is mutually compared.

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