Engineering topics

Cao, Yanan

Publications and source records attributed to Cao, Yanan.

4 records

DOE OSTI2022

A graph signal processing‐based multiple model Kalman filter ( GSP‐MMKF ) tool for predictive analytics: An air separation unit process application

Abstract The industrial Air Separations Unit (ASU) is a complicated and tightly operated process. The use of dynamic process analytics is also a key element of safe and economic operation of these processes, with increasing focus on predictive analytics to take preemptive actions. With the availability of real‐time data from hundreds of sensors, the data analysis process should also consider the topology of the data, as seen in sensor networks. In this paper, a novel tool is presented that considers the complex connectivity patterns in the sensor network and uses local adaptive disturbance estimations to predict global network‐scale trends. The paper introduces the emerging field of Graph Signal Processing (GSP) and presents a rigorous derivation of the tool starting from the extraction of the sensor‐network (in a graph theoretical sense) from the data. This network, which is in the form of a matrix, is then used to derive a Kalman‐filter type of state‐space model driven by input disturbances. Multiple disturbance models (e.g., step, ramp, periodic) are included to allow the model to have different kinds of disturbance propagation. Each graph node (representing the sensors used) dynamically adapts to the most recent detected disturbance individually. These estimated disturbances are propagated to the global network using the graph. Modifications to ensure stability are also discussed. The fidelity of the tool is tested on certain downtime events and the paper concludes by discussing the advantages of the method and planned future improvements.

Ghosh, Sambit↗

DOE OSTI2022

Process prediction and detection of faults using probabilistic bidirectional recurrent neural networks on real plant data

Attaining Industry 4.0 for manufacturing operations requires advanced monitoring systems and real-time data analytics of plant data, among other topics. We propose a Probabilistic Bidirectional Recurrent Network (PBRN) for industrial process monitoring for the early detection of faults. The model is based on a Gated Recurrent Unit (GRU) neural network that allows the model to retain long-term dependencies between sensor data along a time horizon, hence learning the dynamic behavior of the process. To reduce the false-positive detection rate of the model, we compel the model to learn from a highly noisy sensor reading while outputting noise-free sensor outputs. The performance of the proposed model is compared to other data-driven statistical process monitoring schemes using real plant data from an industrial Air Separations Unit (ASU) containing noisy sensor readings. We show that the model can learn from noisy data without reducing its performance. Using two different fault cases, we demonstrate the model’s ability to carry out early fault detection with average false-positive rates of 2.9% and 4.9% for both fault cases. The missed detection rates are 0.1% and 0.2%, respectively.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

A data-driven linear formulation of the optimal demand response scheduling problem for an industrial air separation unit

Demand response (DR) has become a key element in balancing the power grid as the contribution of time-varying renewable power generation increases. Chemical plants are appealing candidates for DR programs as they offer large, concentrated and flexible loads. DR participation calls for frequent production rate changes over time scales that overlap with the dominant dynamics of the plant. Production scheduling should therefore consider the process dynamics explicitly. Here we present a data-driven approach for modelling the scheduling-relevant dynamics based on historical closed-loop operating data using autoregressive with extra inputs (ARX) models. We introduce a new, linear scheduling problem formulation based on the ARX representation, and demonstrate its implementation on an industrial air separation unit.

42 ENGINEERING↗

DOE OSTI2021

Identification and Online Updating of Dynamic Models for Demand Response of an Industrial Air Separation Unit

Demand-response operation of air separation units requires frequent changes in production rate(s), and scheduling calculations must explicitly consider process dynamics to ensure feasibility of the solutions. To this end, scale-bridging models (SBMs) approximate the scheduling-relevant dynamics of a process and its controller in a low-order representation. In contrast to previous works that have employed nonlinear SBMs, this paper proposes linear SBMs, developed using time-series analysis, to facilitate online scheduling computations. Using a year-long industrial dataset, we nd that compact linear SBMs are suitable approximations over typical scheduling horizons, but that their accuracies are unpredictable over time. We introduce a strategy for online updating of the SBMs, based on Kalman ltering schemes for online parameter estimation. The approach greatly improves the accuracy of SBM predictions and will enable the use of linear SBM-based demand-response scheduling in the future.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗