Thousands of process and equipment measurements are gathered by the modern
digital process control systems that are deployed in refineries and
chemical plants. Several years of these data are historized in databases
for analysis and reporting. These databases can be mined for the data
patterns that occur during normal operation and those patterns used to
determine when the process is behaving abnormally.These normal operating
patterns are represented by sets of models. These models include simple
engineering equations, which express known relationships that should be
true during normal operations and multivariate statistical models based
on a variation of principle component analysis. Equipment and process
problems can be detected by comparing the data gathered on a minute by
minute basis to predictions from these models of normal operation. The
deviation between the expected pattern in the process operating data and
the actual data pattern are interpreted by fuzzy Petri nets to determine
the normality of the process operations. This is then used to help the
operator localize and diagnose the root cause of the problem.