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 with 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.