An adaptive metaheuristic optimization approach for Tennessee Eastman process for an industrial fault tolerant control system

Faizan E. Mustafa, Ijaz Ahmed*, Abdul Basit, Mohammed Alqahtani, Muhammad Khalid*

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review


The Tennessee Eastman Process (TEP) is widely recognized as a standard reference for assessing the effectiveness of fault detection and false alarm tracking methods in intricate industrial operations. This paper presents a novel methodology that employs the Adaptive Crow Search Algorithm (ACSA) to improve fault identification capabilities and mitigate the occurrence of false alarms in the TEP. The ACSA is an optimization approach that draws inspiration from the observed behavior of crows in their natural environment. This algorithm possesses the capability to adapt its search behavior in response to the changing dynamics of the optimization process. The primary objective of our research is to devise a monitoring strategy that is adaptable in nature, with the aim of efficiently identifying faults within the TEP while simultaneously minimizing the occurrence of false alarms. The ACSA is applied in order to enhance the optimization of monitoring variables, alarm thresholds, and decision criteria selection and configuration. When compared to traditional static approaches, the ACSA-based monitoring strategy is better at finding faults and reducing false alarms because it adapts well to changes in process dynamics and disturbances. In order to assess the efficacy of our suggested methodology, we have conducted comprehensive simulations on the TEP dataset. The findings suggest that the monitoring strategy based on ACSA demonstrates superior fault identification rates while concurrently mitigating the frequency of false alarms. In addition, the flexibility of ACSA allows it to efficiently manage process variations, disturbances, and uncertainties, thereby enhancing its robustness and reliability in practical scenarios. To validate the effectiveness of our proposed approach, extensive simulations were conducted on the TEP dataset. The results indicate that the ACSA-based monitoring strategy achieves higher fault detection rates while simultaneously reducing the occurrence of false alarms. Moreover, the adaptability of ACSA enables it to effectively handle process variations, disturbances, and uncertainties, making it robust and reliable for real-world applications. The contributions of this research extend beyond the TEP, as the adaptive monitoring strategy utilizing ACSA can be applied to other complex industrial processes. The findings of this study provide valuable insights into the development of advanced fault detection and false alarm monitoring techniques, offering significant benefits in terms of process safety, reliability, and operational efficiency.

Original languageEnglish
Article numbere0296471
JournalPLoS ONE
Issue number2 February
StatePublished - Feb 2024

Bibliographical note

Publisher Copyright:
© 2024 Mustafa et al. This is an open access article distributed under the terms of the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and source are credited.

ASJC Scopus subject areas

  • General


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