This paper introduces a novel hybrid
process monitoring
model that
integrates long short-term memory autoencoders with process controllers’
models. The parameters of the hybrid model are optimized by minimizing
a novel loss function, which combines the mean square error (MSE)
between controlled variables and their reconstructions from the LSTM-AE
model, along with the MSE of manipulated variables and their reconstructions
obtained with the numerically implemented and exactly a priori known
controller equations. The effectiveness of the proposed method is
evaluated on the benchmark of an industrial-scale penicillin process
as a batch case study and the Tennessee Eastman plant process under
a decentralized control strategy as a continuous case study. A comparative
analysis of the proposed hybrid model with an equivalent nonhybrid
LSTM-AE model, which does not utilize process controllers’
equations, highlights the superiority of the proposed hybrid monitoring
model in fault detection. These improvements result from the use of
an LSTM-AE network with fewer parameters, thus making it less susceptible
to overfitting.