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Detection of Plant Incident Patterns by using Document Classification Technique
- 1. Detection of Plant Incident Patterns by using Document Classification Technique Toru Nakata Artificial Intelligence Research Center, National Institute of Advanced Science and Technology (AIST), Japan. torunakata@gmail.com 1
- 2. Huge verbal data sets on industrial safety 1. Aviation Safety Reporting System (ASRS) – Collected by NASA. – Reports on aviation incidents written by pilots and other workers involved. – Web site provides 199 057 reports of incidents from Jan 1988 to Nov 2018. – In this study, 4 469 reports (with 1 365 260 words) of all incidents in 2013 are used. 2. JPEC SAFER Database – Collected by Japan Petroleum Energy Center (JPEC) – 425 reports on (rather severe) incidents occurred in oil refineries in the world. 2
- 3. An example of ASRS report I told her that it was 11 minutes until scheduled departure. I had also informed the gate agents twice during boarding that oversized carry-on baggage was entering the aircraft. The agent Supervisor stated that the cargo bin had already closed. … 3 (This is a fragment. The original report is much longer.)
- 4. PART 1. REPORT TREE — TO DETECT PATTERNS OF INCIDENTS 4
- 5. Approach: Document Classification A valve on the bottom of CDU got stuck. An elbow on a pipe of VDU got corrosion. A valve on the bottom of VDU got stuck. An elbow on a pipe of CDU got corrosion. Report A Report C Report B Report D 5
- 6. Watch only keywords: Regard a report as a bag-of-words valve bottom CDU stick elbow pipe VDU corrosion valve bottom VDU stick elbow pipe CDU corrosion Report A Report C Report B Report D 6
- 7. Consider similarity/difference valve bottom CDU stick elbow pipe VDU corrosion valve bottom VDU stick elbow pipe CDU corrosion Report A Report C Report B Report D 1 difference 1 difference 3 differences 3 differences 7
- 8. Arrange the reports in a tree graph Report A Report C Report B Report D valve bottom CDU stick elbow pipe VDU corrosion valve bottom VDU stick elbow pipe CDU corrosion To keep simplicity, the tree graph does not represent amount of difference explicitly. Order of differences are expressed with the branching order. 8
- 9. NASA ASRS Report Tree (4 469 Reports) Labels are report ID numbers. 9
- 10. NASA ASRS Report Tree (4 469 Reports) Airplane Equipment Failure Cockpit Equipment Failure Autopilot Failure Engine Trouble Troubles on Own Airplane during Level Flight Troubles of Approach Course Control Near-miss with Other Traffic during Level Flight Near-miss during Departure Troubles on Ground or Landing Troubles during Taxing 10
- 11. Tank, Oil spillageFire Disaster Explosion Leak, valve damage Topper, desulphurization equipment, erosion, leak, fire Naphtha tank, Explosion Floating-roof tank incidents Flange, over tightening, leak Valve failuresDrain valve, leak Safety valve chattering JPEC SAFER Report Tree 11
- 12. PART 2. WORD TREE — TO UNDERSTAND CONTENTS OF INCIDENTS 12
- 13. Watch only keywords valve bottom CDU stick elbow pipe VDU corrosion valve bottom VDU stick elbow pipe CDU corrosion Report A Report C Report B Report D 13
- 14. Count Co-occurrence of Keywords valve bottom stick CDU VDU elbow pipe corrosion valve - 2 2 1 1 0 0 0 bottom 2 - 2 1 1 0 0 0 stick 2 2 - 1 1 0 0 0 CDU 1 1 1 - 0 1 1 1 VDU 1 1 1 0 - 1 1 1 elbow 0 0 0 1 1 - 2 2 pipe 0 0 0 1 1 2 - 2 corrosion 0 0 0 1 1 2 2 - Number of co-occurrence within each report of word-pair valve bottom CDU stick elbow pipe VDU corrosion valve bottom VDU stick elbow pipe CDU corrosion 14
- 15. Arrange the words in a tree graph valve bottom elbow pipe stick corrosion CDU VDU 15
- 16. ASRS Word Tree Collision Thinking Navigation Decision, or general words Engine Gear Coping Trouble, Emergency, Rescue Maintenance, Ground crew Approaching to Airport Landing Traffic Control around Airport Attitude and Speed Control 16
- 17. Vaper cloud, explosion suffocation Pipe, pinhole Pip wall thinning Safety, Countermea sure external corrosion hydrogenation desulfurizing equipment , elbow rupture Alarm, steam, Anomaly Drain valve, heavy oil, Vacuum distillation Fluidized catalytic cracker, Sea, spillage, oil retaining wall, roof- tank Burner, heating furnace, flame Fire disaster, Emergency stop Flange, gasket, bolts Inner pressure, spouting JPEC SAFER Word Tree 17
- 18. Summery • Problem: Verbal information is important but too large to read. • Solution: Text Classification • Result: – Applied incident reports of oil refineries. – Spotted typical trouble patterns. • Further Application: – To find the worst incident that are very close to minor troubles reported in your own plant. And to evaluate the risk of minor troubles. 18