Integration of principal component analysis and fuzzy logic systems for comprehensive process fault detection and diagnosis

A fault diagnosis system is developed by integrating principal component analysis (PCA) with fuzzy logic knowledge-based (FLKB) systems. A PCA model is created using normal state data. Then it is used to project normal and faulty data during the training stage. It evaluates the process variables values and their correlation, allowing fast and reliable fault detection. Once detection is performed, a FLKB system is used to evaluate the contributions of each variable to changes in the process, finding the root causes of the abnormal event detected. A simple methodology to automatically extract compact process information is presented. Then, an optimization algorithm is implemented to improve the isolation performance. The methodology is demonstrated in an academic case study and in the Tennessee Eastman process benchmark.