Incipient Fault Detection for Multiphase Batch Processes With Limited Batches

Sufficient batches are in general, required for fault detection of batch processes. However, sometimes, it is difficult and may be impractical to conduct multiple cycles and wait until enough batches are available. Without batch-wise normalization step, the nonstationary cannot be efficiently removed by time-wise normalization. The mean values of the nonstationary variables are still time varying and the interval of fault-free data is very wide in each phase. Therefore, the incipient fault, which has a small magnitude including early changing and the slow developing, may be buried by nonstationary trends resulting in low fault detection rate. To address the above issue, a two-layer fault detection method is proposed to detect the incipient fault for multiphase batch processes with limited batches. First, a concurrent variable separation strategy is proposed to distinguish nonstationary variables from stationary variables for multiple batches in each phase. Second, a two-layer fault detection model is constructed to detect the incipient fault. Cointegration analysis-based fault detection model is built to investigate the relationship between nonstationary variables, which can effectively distinguish the incipient fault from the normal trend of the nonstationary variables. Principal component analysis is adopted to describe the correlation of stationary variables. Afterward, a total fault detection model is constructed to monitor the relation between nonstationary variables and stationary variables. To illustrate the feasibility and effectiveness, the proposed algorithm is applied to two multiphase batch processes including fed-batch penicillin fermentation process and semiconductor etch process.