Multivariate Sensor Data Analysis for Oil Refineries and Multi-mode Identification of System Behavior in Real-time

Large-scale oil refineries are equipped with mission-critical heavy machinery (boilers, engines, turbines, and so on) and are continuously monitored by thousands of sensors for process efficiency, environmental safety, and predictive maintenance purposes. However, sensors themselves are also prone to errors and failure. The quality of data received from these sensors should be verified before being used in system modeling. There is a need for reliable methods and systems that can provide data validation and reconciliation in real-time with high accuracy. In this paper, we develop a novel method for real-time data validation, gross error detection and classification over multivariate sensor data streams. The validated and high-quality data obtained from these processes is used for pattern analysis and modeling of industrial plants. We obtain sensor data from the power and petrochemical plants of an oil refinery and analyze them using various time-series modeling and data mining techniques that we integrate into a complex event processing engine. Next, we study the computational performance implications of the proposed methods and uncover regimes where they are sustainable over fast streams of sensor data. Finally, we detect shifts among steady-states of data, which represent systems’ multiple operating modes and identify the time when a model reconstruction is required using DBSCAN clustering algorithm.