Patent ID: 7451003

Claim:
A method of monitoring, validation and analysis for a process control system having normal process data and sensors, and represented by a plurality of primary process models and a plurality of process variables, comprising: generating a plurality of primary residual process models derived from said primary process models, said normal process data, and one or more statistical parameters corresponding to said normal process data; measuring real-time sensor data; computing primary residual values of said primary residual process models corresponding to said real-time sensor data; deriving an expected value for one or more of said primary residual values from historical normal process data; determining deviations of said primary residual values from said corresponding expected values; mapping one or more of said deviations of said primary residual values from said corresponding expected values into one or more compressed values; automatically generating one or more fuzzy logic diagnostic rules; computing a certainty factor for a possible fault by applying said fuzzy logic diagnostic rules to said compressed values; and displaying said certainty factor on a monitor, computer screen or control console used for monitoring, validation and analysis for a process control system.