An integrated approach combining randomized kernel PCA, Gaussian mixture modeling and ICA for fault detection in non-linear processes

Abstract Principal component analysis (PCA) and independent component analysis (ICA), as well as their kernel extensions, have been widely applied in the past for industrial fault detection with Gaussian or non-Gaussian process data with linear or non-linear characteristics. Kernel-based techniques lead to computational complexity due to the high dimensionality of the dataset in the feature space. In this work, a randomization approach is used to obtain a low-rank approximation of the high-dimensional kernel matrix. A hybrid machine learning technique is proposed that integrates randomized kernel PCA (RKPCA) with ICA and Gaussian mixture modeling (GMM). The proposed approach, ICA-RKPCA-GMM, addresses the Gaussian and non-Gaussian characteristics of non-linear process data. Another hybrid algorithm combining three basic techniques of ICA, PCA and GMM is also developed (ICA-PCA-GMM). The fault detection performances of the proposed techniques (ICA-RKPCA-GMM and ICA-PCA-GMM) are compared with PCA, ICA, KPCA and combined ICA-PCA techniques by applying the techniques to two benchmark systems. Monitoring performances were evaluated by determining the false alarm rate and fault detection rate for different types of process and sensor faults. The simulation results show that the proposed ICA-RKPCA-GMM approach yields better results than individual ICA, PCA and KPCA techniques, the combined ICA-PCA and the proposed ICA-PCA-GMM technique.