Stream-data-clustering based adaptive alarm threshold setting approaches for industrial processes with multiple operating conditions

The setting of alarm thresholds is a critical concern of alarm management systems in industrial processes. Conventional alarm thresholds less consider changes of operating conditions in production processes, which degrades the effectiveness of alarm management systems. In response to this problem, this paper proposes an adaptive alarm threshold setting approach based on stream data clustering (SDC). Firstly, we develop a stream data clustering algorithm termed as a-DenStream algorithm which realizes industrial flow data clustering through online micro-clustering and offline integration. Subsequently, we develop the C-BOUND algorithm to extract the edges of the clustering results. In response to alarms associated with multiple operating conditions, segmentations are conducted to set alarm threshold groups and build a multi-condition alarm threshold model. Consequently, an adaptive alarm threshold setting method based on model matching is created. The effectiveness of the proposed method is demonstrated by experiments on a coal gasification chemical process. The proposed method provides a potential application for industrial processes with multiple operating conditions alarm managements. •An improved stream data clustering method devoted to alarm data analyses is proposed.•An adaptive alarm threshold setting (AATS) approach is proposed.•AATS approach considered shifted operating conditions of chemical production process.•The performances of the proposed AATS approach are validated through case studies.