Local–Global Modeling and Distributed Computing Framework for Nonlinear Plant-Wide Process Monitoring With Industrial Big Data

Abstract

Industrial big data and complex process nonlinearity have introduced new challenges in plant-wide process monitoring. This article proposes a local-global modeling and distributed computing framework to achieve efficient fault detection and isolation for nonlinear plant-wide processes. First, a stacked autoencoder is used to extract dominant representations of each local process unit and establish the local inner monitor. Second, mutual information (MI) is used to determine the neighborhood variables of a local unit. Afterward, a joint representation learning is then performed between the local unit and the neighborhood variables to extract the outer-related representations and establish the outer-related monitor for the local unit. Finally, the outer-related representations from all process units are used to establish global monitoring systems. Given that the modeling of each unit can be performed individually, the computation process can be efficiently completed with different CPUs. The proposed modeling and monitoring method is applied to the Tennessee Eastman (TE) and laboratory-scale glycerol distillation processes to demonstrate the feasibility of the method.