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Application of unthresholded recurrence plots and texture analysis for industrial loops with faulty valves

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Abstract

As one of the most important elements of a control loop, control valves are essential assets to the plant because they ensure the high quality of products, as well as the safety of personnel and equipment (Abbasi et al. in J Hydrol, 597:125717, 2021). Unfortunately, control valves tend to suffer from many issues, and stiction is one of the long-standing faults that results in oscillations in important process variables which are highly undesirable. In the present work, unthresholded recurrence plots and texture analysis previously developed for mining industry (Kok et al. in IFAC-PapersOnLine 52:36-41, 2019) is applied to diagnose stiction in process control loops. Texture features are extracted from distance matrices derived from typical control-loop OP-PV data generated from a valve stiction model. A neural network model is then trained based on the extracted features. The optimised classification model is then applied in industrial control loops to identify the presence of stiction. The results from 78 benchmark industrial loops with varying faulty issues show a comparable performance with the recent methods reported in the literature.

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Acknowledgements

The authors would like to thank Universiti Teknologi PETRONAS (UTP), Malaysia and Curtin University, Australia for the technical support provided to complete this work. The authors also would like to thank The Ministry of Science, Technology, and Innovation of Malaysia which has funded this work via the eScienceFund (Project No.: 03-02-02-SF0236).

Funding

The authors also would like to thank The Ministry of Science, Technology, and Innovation of Malaysia which has funded this work via the eScienceFund (Project No.: 03-02-02-SF0236).

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Authors and Affiliations

  1. Department of Chemical Engineering, Universiti Teknologi PETRONAS, 32610, Bandar Seri Iskandar, Perak, Malaysia

    Tze Lin Kok & Haslinda Zabiri

  2. Western Australian School of Mines, Curtin University, GPO Box U1987, Perth, WA, 6844, Australia

    Chris Aldrich & Jacques Olivier

  3. CO2RES, Institute of Contaminant Management, Universiti Teknologi PETRONAS, 32610, Bandar Seri Iskandar, Perak, Malaysia

    Haslinda Zabiri

  4. Chemical Engineering Department, NED University of Engineering and Technology, Karachi, 75270, Pakistan

    Syed Ali Ammar Taqvi

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  1. Tze Lin Kok
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  2. Chris Aldrich
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  4. Syed Ali Ammar Taqvi
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  5. Jacques Olivier
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Correspondence to Haslinda Zabiri.

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All authors have participated in (a) conception and design, or analysis and interpretation of the data; (b) drafting the article or revising it critically for important intellectual content; and (c) approval of the final version. This manuscript has not been submitted to, nor is under review at, another journal or other publishing venue. The authors have no affiliation with any organization with a direct or indirect financial interest in the subject matter discussed in the manuscript.

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Kok, T.L., Aldrich, C., Zabiri, H. et al. Application of unthresholded recurrence plots and texture analysis for industrial loops with faulty valves. Soft Comput 26, 10477–10492 (2022). https://doi.org/10.1007/s00500-022-06894-3

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