Uniformance® Asset Sentinel R531.

1
Model Library Guide

UASDOC-X481-en-531.1A

May 2020
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Table of contents

1 Introduction ......................................................................................................................................................................9
1.1 Model Based approach ................................................................................................................................................................... 9
1.2 Performance Monitoring Models in Uniformance Asset Sentinel .......................................................................... 10
1.3 Equipment Performance Monitoring ................................................................................................................................... 11

Content Deployment ................................................................................................................................................... 14

2.1 Import Asset Types......................................................................................................................................................................... 14
2.2 Import and Configure UI Templates ...................................................................................................................................... 15

Centrifugal Pump Monitoring ................................................................................................................................. 19

3.1 Process Performance Monitoring .......................................................................................................................................... 20
3.2 Energy Monitoring ......................................................................................................................................................................... 22

3.3 Performance Monitoring ............................................................................................................................................................ 23

3.4 Failure Modes ................................................................................................................................................................................... 27
3.5 Configuration ................................................................................................................................................................................... 29

Centrifugal Compressor Monitoring ..................................................................................................................... 34

4.1 Process Performance Monitoring .......................................................................................................................................... 35
4.2 Energy Monitoring ......................................................................................................................................................................... 37

4.3 Performance Monitoring ............................................................................................................................................................ 38

4.4 Failure Modes ................................................................................................................................................................................... 42
4.5 Configuration ................................................................................................................................................................................... 44

AC Motor Monitoring .................................................................................................................................................. 49

5.1 Process Performance Monitoring .......................................................................................................................................... 50
5.2 Performance Monitoring ............................................................................................................................................................ 50

5.3 Failure Modes ................................................................................................................................................................................... 52

5.4 Configuration ................................................................................................................................................................................... 53

DC Motor Monitoring .................................................................................................................................................. 56

6.1 Process Performance Monitoring .......................................................................................................................................... 57

6.2 Performance Monitoring ............................................................................................................................................................ 57

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 6.3 Failure Modes ................................................................................................................................................................................... 59
6.4 Configuration ................................................................................................................................................................................... 60

Liquid Phase Valve Monitoring ............................................................................................................................... 63

7.1 Process Performance Monitoring .......................................................................................................................................... 64
7.2 Performance Monitoring ............................................................................................................................................................ 65
7.3 Failure Modes ................................................................................................................................................................................... 67
7.4 Configuration ................................................................................................................................................................................... 68

Two Phase Valve Monitoring .................................................................................................................................... 71

8.1 Process Performance Monitoring .......................................................................................................................................... 72
8.2 Performance Monitoring ............................................................................................................................................................ 73
8.3 Failure Modes ................................................................................................................................................................................... 75
8.4 Configuration ................................................................................................................................................................................... 76

Furnace Monitoring .................................................................................................................................................... 80

9.1 Process Performance Monitoring .......................................................................................................................................... 82

9.2 Energy Monitoring ......................................................................................................................................................................... 83
9.3 Performance Monitoring ............................................................................................................................................................ 83

9.4 Failure Modes ................................................................................................................................................................................... 86

9.5 Configuration ................................................................................................................................................................................... 88

Steam Turbine Monitoring........................................................................................................................................ 94

10.1 Process Performance Monitoring .......................................................................................................................................... 95

10.2 Energy Monitoring ......................................................................................................................................................................... 96
10.3 Performance Monitoring ............................................................................................................................................................ 96

10.4 Failure Modes ................................................................................................................................................................................... 98

10.5 Configuration ................................................................................................................................................................................... 99

Shell and Tube Heat Exchanger Monitoring ................................................................................................... 104

11.1 Process Performance Monitoring ....................................................................................................................................... 105

11.2 Performance Monitoring ......................................................................................................................................................... 106
11.3 Failure Modes ................................................................................................................................................................................ 112

11.4 Configuration ................................................................................................................................................................................ 114

Cooling Tower Monitoring ..................................................................................................................................... 120

12.1 Process Performance Monitoring ....................................................................................................................................... 121

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 12.2 Performance Monitoring ......................................................................................................................................................... 122
12.3 Failure Modes ................................................................................................................................................................................ 123
12.4 Configuration ................................................................................................................................................................................ 124

Air Preheater Monitoring ........................................................................................................................................ 129

13.1 Process Performance Monitoring ....................................................................................................................................... 130
13.2 Performance Monitoring ......................................................................................................................................................... 130
13.3 Failure Modes ................................................................................................................................................................................ 131
13.4 Configuration ................................................................................................................................................................................ 132

Centrifugal Fan Monitoring ................................................................................................................................... 135

14.1 Process Performance Monitoring ....................................................................................................................................... 136
14.2 Performance Monitoring ......................................................................................................................................................... 137
14.3 Failure Modes ................................................................................................................................................................................ 138
14.4 Configuration ................................................................................................................................................................................ 139

Diesel Generator Monitoring ................................................................................................................................ 144

15.1 Process Performance Monitoring ....................................................................................................................................... 145
15.2 Performance Monitoring ......................................................................................................................................................... 146

15.3 Failure Modes ................................................................................................................................................................................ 148

15.4 Configuration ................................................................................................................................................................................ 149

Electrical Submersible Pump Monitoring ........................................................................................................ 152

16.1 Process Performance Monitoring ....................................................................................................................................... 153

16.2 Performance Monitoring ......................................................................................................................................................... 154
16.3 Failure Modes ................................................................................................................................................................................ 155

16.4 Configuration ................................................................................................................................................................................ 157

Fired Heater Monitoring ......................................................................................................................................... 160

17.1 Process Performance Monitoring ....................................................................................................................................... 161

17.2 Energy Monitoring ...................................................................................................................................................................... 162

17.3 Performance Monitoring ......................................................................................................................................................... 162
17.4 Failure Modes ................................................................................................................................................................................ 164

17.5 Configuration ................................................................................................................................................................................ 166

Cartridge Filter Monitoring.................................................................................................................................... 174

18.1 Process Performance Monitoring ....................................................................................................................................... 175

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 18.2 Performance Monitoring ......................................................................................................................................................... 175
18.3 Failure Modes ................................................................................................................................................................................ 176
18.4 Configuration ................................................................................................................................................................................ 177

Reciprocating Compressor Monitoring ............................................................................................................. 179

19.1 Process Performance Monitoring ....................................................................................................................................... 180
19.2 Performance Monitoring ......................................................................................................................................................... 180
19.3 Failure Modes ................................................................................................................................................................................ 183
19.4 Configuration ................................................................................................................................................................................ 184

Gas Turbine Monitoring .......................................................................................................................................... 187

20.1 Process Performance Monitoring ....................................................................................................................................... 188
20.2 Performance Monitoring ......................................................................................................................................................... 189
20.3 Failure Modes ................................................................................................................................................................................ 190
20.4 Configuration ................................................................................................................................................................................ 192

Boiler Monitoring ...................................................................................................................................................... 201

21.1 Process Performance Monitoring ....................................................................................................................................... 202
21.2 Energy Monitoring ...................................................................................................................................................................... 204

21.3 Performance Monitoring ......................................................................................................................................................... 205

21.4 Failure Modes ................................................................................................................................................................................ 207
21.5 Configuration ................................................................................................................................................................................ 209

HRSG Monitoring ...................................................................................................................................................... 212

22.1 Process Performance Monitoring ....................................................................................................................................... 213
22.2 Energy Monitoring ...................................................................................................................................................................... 215

22.3 Performance Monitoring ......................................................................................................................................................... 215

22.4 Failure Modes ................................................................................................................................................................................ 217
22.5 Configuration ................................................................................................................................................................................ 218

Plate and Frame Heat Exchanger ....................................................................................................................... 221

23.1 Process Performance Monitoring ....................................................................................................................................... 222
23.2 Performance Monitoring ......................................................................................................................................................... 223

23.3 Failure Modes ................................................................................................................................................................................ 225

23.4 Configuration ................................................................................................................................................................................ 226

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 Asset Management Metrics................................................................................................................................... 230

UniSim Design (USD) Integration ....................................................................................................................... 231

25.1 USD Snapshots............................................................................................................................................................................. 231
25.2 USD Parameters........................................................................................................................................................................... 232
25.3 Simulator Interface ..................................................................................................................................................................... 232
25.4 Optimizer Interface ..................................................................................................................................................................... 233

Appendix: APR Templates ...................................................................................................................................... 235

26.1 Introduction.................................................................................................................................................................................... 235
26.2 Templated Content ..................................................................................................................................................................... 237
26.3 Implementation Workflow ....................................................................................................................................................... 256
26.4 Data Requirements ..................................................................................................................................................................... 258

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About this guide

Revision history

Revision Date Description

A 05/20 Initial release of this document.

Intended audience

Operations

Related documents

The following list identifies publications that may contain information relevant to the information in this
document.

Document name Document number

Uniformance® Asset Sentinel User’s Guide UASDOC-X392-en-531.1A

Uniformance® Asset Sentinel Configuration Guide UASDOC-X391-en-531.1A
Uniformance® Asset Sentinel Installation Guide UASDOC-X390-en-531.1A
Uniformance® Asset Sentinel R520.3 Software Change Notice UASDOC-X166-en-531.1A

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1 Introduction

The performance of all critical equipment deteriorates over a time resulting in lost performance,
increased energy usage, and reduced throughput. Continuous monitoring of machine vibration, thrust,
and bearing temperatures as part of condition monitoring is essential for reliable and safe operation of
turbo machinery. But this information is not sufficient for operators to maximize revenue and minimize
maintenance expenses. The process performance monitoring evaluates the effect of the process
changes on the asset performance so that the operator can select better operating regimes and predict
accurate maintenance schedules. This is also required to diagnose the process failures and find out
better operating conditions.

As the performance of gas turbines, steam turbines, heat exchangers, compressors, and other types of
process equipment deteriorates over time, their efficiency decreases, power consumption increases,
throughput reduces and operating costs rises. A comprehensive performance monitoring along with
process performance offers an effective way to off-set the above problems. The combination of process
performance monitoring (based on thermodynamic models) and mechanical condition monitoring
(such as vibration) can thus allow better diagnostic capabilities for assessing the nature, severity,
location, and cause of machinery performance changes. Identification of deviation between actual and
design performance is vital in equipment performance monitoring for rotating equipment.

1.1 Model Based approach

A Performance Monitoring Model is used to calculate the operating (actual) performance output, design
(expected) performance output, and deviations between the operating performance and design
performance output.

The operating performance output is calculated using the measured operating conditions taken from
existing instruments or historian whereas, the design performance output is calculated using the
performance curves data. The performance curves or design data of an equipment is the input data
obtained from the Original Equipment Manufacturer (OEM).

The deviation performance outputs are used to monitor the degradation in performance of the
equipment such as Pump, Compressor, Turbine, and Heat Exchanger.

The performance outputs are used to:

o Monitor on-line (real time) condition as part of an integrated monitoring system.
o Diagnose the sources of degradation by configuring faults, symptoms, and fault models on
performance output such as power, efficiency, flow rate, head, and so on.
o Determine the power and efficiency degradation of gas turbines, gas turbine components, steam
turbines, shell and tube heat exchanger, centrifugal compressors, and centrifugal pumps.

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 o Analyze the performance degradation.
o Analyze the source using fault management and fault history.
o Trend the performance outputs for monitoring the equipment conditions.

1.2 Performance Monitoring Models in

Uniformance Asset Sentinel
Process Performance Monitoring Models in Uniformance Asset Sentinel help you do the following:
o Use faults, symptoms and fault models so your operators can be informed about the potential
damage in assets under unfavorable operating conditions.
o Use fault management for KPIs, so your operators can be informed about violations of the nominal
asset operating range and deviations from the expected characteristics.
o Run the process more efficiently with the help of online thermodynamic based performance
calculations for process equipment.
o Track key performance indicators in real-time and compare against target operation values.
o Improve operating margins by avoiding unnecessary shutdowns.
o Prioritize and plan maintenance activities with better decision making.

The following performance monitoring models can be configured in Uniformance Asset Sentinel:
o Centrifugal Pump
o Centrifugal Compressor
o Shell and Tube Heat Exchanger
o Steam Turbine
o AC Motor
o DC Motor
o Gas Turbine
o HRSG
o Liquid Phase Valve
o Two Phase Valve
o Boiler
o Furnace
o Reciprocating Compressor
o Diesel Generator
o Fan
o Air Preheater
o Plate & Frame Heat Exchanger

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 o Cartridge Filter
o Cooling Tower
o Fired Heater
o Electrical Submersible Pump
NOTES
Only the fixed data units for performance monitoring models are supported. All the models and
measured input data must correspond to the selected units.
You must ensure that correct data units are used for the measured data instrumentation.

1.3 Equipment Performance Monitoring

Design Data
The models used in performance monitoring are supplemented with design data provided with
equipment, at delivery or acceptance. The design data allows two important elements of performance
monitoring to be implemented:
o Characterization of individual equipment
o Reference or expected performance of an equipment

The accurate equipment design data must be specified for design performance calculations and to
compare operating performance with design performance.

Equipment Modeling
Performance monitoring calculation engine operates to interface plant data with a mathematical
representation of the equipment. Design curves are interpreted within the system to supplement the
chemical engineering model, and the software generates performance indicators that apply to the
current operation.

Design data for a piece of process equipment is applied to standard “chemical engineering”
mathematical models to create a detailed model that operates over the equipment's expected operating
envelope. It is important to recognize that a mathematical model requires a minimum number of defined
variables in order to perform the required calculations. Given the defined variables as inputs to the
model, the results can be said to be predictions of a machine's behavior under the input conditions. For
most mechanical models of process equipment, the inlet conditions are defined, and the outlet
conditions are predicted. The input data can be either required or optional data. The default data can be
used for optional data for some of the variables.

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Fault Modeling
Faults and its symptoms are used to detect anomalies with the equipment or process. It helps to monitor
the health of the equipment that covers reliability aspect. Fault symptom model explains the event rules
defined to monitor health with predefined recommended actions. The parameters can be monitored by
below ways.

Design Limits: The parameters are compared with their applicable design high, low limits and events are
generated in case of limit violation.

Statistical limits: The current value is compared with last 1 hour’s average value and events are
generated in case current value is having more than 2 to 5 sigma deviation.

APR limits: The Advanced Pattern Recognition (APR) tool can predict expected values for health
monitoring parameters based on defined correlation model and chosen calibration period used to train
the model. The current values are compared with expected values and events are generated if deviation
exceeds 2 to 5 sigma.

Performance Monitoring
The results of performance monitoring can be analyzed to determine the effective performance of the
machine. This indicates any maintenance need and the relative timing of the activity.

This is possible through a variety of mechanisms - the most obvious is to simply look at machine
performance trends, particularly with respect to previously performed maintenance to determine its
effectiveness and determine the need for the further activity. It is also possible to assign a cost to the
degradation. When combined with an associated maintenance cost, an effective indicator of the optimal
time to perform the maintenance can be easily produced. In general, it is important to recognize that
machine performance is defined as much by its current operation, as by any degradation it may exhibit.
To this end, the deviation from design, or expected performance, is arguably a more important indicator
than the “spot value” of performance. A good performance monitoring system provides both actual
performance indicators and deviation from design.

Model Input Data

Uniformance Asset Sentinel evaluates the quality of DCS/Historian input signals and issues errors or
warnings in the log file. It also verifies the required data for executing performance calculations and
issue errors or warnings in the log file. The model input measurements or model data must be accurate
because the equipment performance calculations are based on measured data.

Model Default Data

The following are the default values of the input data used in performance models.

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Attribute Name Attribute Value Units

Default Compressibility 1.0

Default Temperature 15 Deg C

Default Pressure 1.01325 bara

Default Molecular Weight (same as air molecular 28.9644

weight)

Error or Warning Messages

Error messages, if any, during execution are displayed in the Uniformance Asset Sentinel log files. An
error message contain a brief description of the error and the name of the asset where the error
occurred. Similarly, warning messages are created in a log file for the respective asset only when the
asset uses the process models for calculations.

Errors may or may not be considered fatal, depending on their impact. In case of fatal errors, the
program exits after the error has been written to the error file. The errors and warnings for non-fatal
condition analysis programs are appended to the error file and the program is allowed to continue. As a
result, the error file may consist of multiple lines of messages.

Example

ERROR 2012-07-15 23:10:21,651 110229ms ExecutionOutputAdapter WriteLogger - Error while

Evaluating 'SteamTurbine101'-'TS_SteamTurbineVariableSpeed': The required input data like Inlet
pressure, Outlet pressure, Inlet temperature, measured speed for variable speed type, are not configured.

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 Content Deployment

2.1 Import Asset Types

Navigate to the following location of the installable to access UAS template resources:
\StandardLibrary\ModelLibrary\

Importing xml
1. Copy the xml from the above location.
2. Paste it to the following location of UAS APP server:
<<Installed Drive>>\Program Files (x86)\Honeywell\MES\AssetManager\Tools\AMImportExport

3. Double click the ImportModels.exe file.

4. Select “Asset Manager Export File” from Source dropdown.
5. Select the models which need to be imported. In below example, case models for Steam Turbine are
imported.
6. Click on Copy Button.
7. On successful import of Asset models, a message indicating the success is displayed at the bottom
left corner.
For example, “The number of models copied is: 2” where 2 is the number of models selected for
import.

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8. Ensure that models are imported successfully. Verify this from the Sentinel User Interface Model
Configuration Tab (Sentinel -> Template Configuration -> Asset Configuration -> Model
Configuration).
Alternately, this can be verified from the logs by clicking on View Logs on the utility at right bottom
corner.

2.2 Import and Configure UI Templates

Deploy HMI Solution Pack (Pre-requisites)
Navigate to the following location from the UAS installable to download HMI Solution pack content:
\StandardLibrary\Sample Graphics\1 Graphics Prerequisites\

Perform the following steps to deploy HMI solution pack:

1. Copy HMI Solution pack content to a local folder e.g. C:\APM HMI Web Solution Pack\
2. Copy the CSS folder from HMI solution pack to the following location:[Installed Drive]\Program Files
(x86)\Honeywell\MES\Core\WWWMESCore\

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3. Copy the contents (files and folder) of the Scripts folder from HMI solution pack to:
[Installed Drive]\Program Files (x86)\Honeywell\MES\WWWMESCommon\Scripts\

HMI Graphics Deployment

1. Navigate to the following location of the UAS installable to download HMI displays:
\StandardLibrary\Sample Graphics\
2. Copy the contents (files and folder) to a local folder
For example, C:\Users\<InstallUser>\Documents\HMIWeb\<ComputerName>
3. Open graphics display using HMI Web Display Builder.
4. Decide on the content of the graphics required to be displayed. Add and/or remove the tags to
update the graphics as per requirement.
Note

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Aggregates associated to the Attribute mappings from Sentinel (UAS) depends on whether that attribute
is historised or not. So, default graphics attributes are mapped to aggregate as ‘END’ (last).
5. Open HMI and open any of the copied sample graphics. Double click on the HMI and go to
appearance tab and do the below changes:
6. Style (example font type and size) for shapes and objects are linked through css file. To map css file:
7. Open Display Properties, under Appearance tab update stylesheet link reflecting the Web Server URL,
pointing to the css location such as the https://<FFQDN>/MES/core/CSS/sp.css file.
For example, if using an https protocol:
https://ceweb.vepsystem.com/MES/core/CSS/sp.css
For example, if using an http protocol:
http://ceweb.vepsystem.com/MES/core/CSS/sp.css

8. Go to the Shape properties.

9. Select time control and data source in stale data shape from the drop down.

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10. Set the Stale Timeout value.
11. Publish the graphics.
12. Associating published graphics to asset template. Follow the steps provided in Section 10 –
Configuring Graphics of UAS Configuration Guide to associate the published graphics to appropriate
assets.

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 Centrifugal Pump Monitoring

P A Centrifugal Pump is a rota dynamic equipment that uses a rotating impeller to increase the pressure
and flow rate of a fluid. It is used to transport liquids or slurries through pipes by centrifugal action.

The centrifugal pumps are by far the most commonly used of the pump types. Among all the installed
pumps in a typical petroleum plant, almost 80–90% are centrifugal pumps.

Centrifugal pumps are widely used because of their design simplicity, high efficiency, wide range of
capacity, head, smooth flow rate, and ease of operation and maintenance.

Due to the variation in flow versus pressure & light to moderate viscous fluid handling ability centrifugal
pumps are more flexible and commonly used in process & pipeline applications.

Centrifugal pumps are capable of providing a wide range of flow rate over a certain pressure range.
Hence, pressure generated by centrifugal pump depends on the flow rate of the pump. The operating
and maintenance cost of centrifugal pumps are lower compared to Positive Displacement pumps.

Around 20% of the world's electrical energy is used by pumps. If a pump fails, it can cause an entire
plant to shut down and the result in losses.

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This document explains centrifugal pump monitoring philosophy for process, performance, energy and
health parameters and their importance.

Monitoring Basic machine health data in addition to pump operating conditions helps to maintain
reliable pump operations. There are three areas that helps to monitor pump performance to increase the
availability and decrease the energy costs.
o Process and condition monitoring
o Energy monitoring
o Performance and Health monitoring

Item Type
Category Equipment
Equipment Class Pump
Equipment Type Centrifugal

Following are the types of centrifugal pumps which are supported in this UAS template:
o Axial Flow Pumps
o Mixed/Radial Flow Pumps
o Peripheral Pumps
o Jet Pumps

3.1 Process Performance Monitoring

The following measured parameters are monitored as it has following impact on performance and health
of the centrifugal pump if not operated in operating range.

Flow rate: The centrifugal pump curve has high and low flow limits, which can cause significant
mechanical damage to the pump if not avoided. At the low flow, flow recirculation can damage a pump,
while at the high flow, excessive NPSHR, horsepower and choke flow can result in mechanical damage to
impellers, casing, shaft, bearings and seals.

API 610 states that a Centrifugal pump should be operated within preferred operating region of 70-120
% of Best Efficiency Point (BEP).

Suction Pressure: When a pump is under low pressure or vacuum conditions, suction cavitation occurs.
The pump is being "starved" or is not receiving enough flow. When this happens, bubbles or cavities will
form at the eye of the impeller. As the bubbles carry over to the discharge side of the pump, the fluid
conditions change, compressing the bubble into liquid and causing it to implode against the face of the
impeller.

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Suction and Discharge temperature: The significant increase in discharge temperature over the suction
temperature indicates degradation in pump efficiency. It may occur due to improper operating
conditions or health issue of the pump.

Discharge Pressure: A lower discharge pressure lower than the desired value indicates either high flow
or the inability of pump to fulfill the head requirement.

Suction and Discharge temperature: The temperature of the fluid at the pump inlet is usually of most
concern as vapor pressure can have a significant effect on pump performance. The significant increase
in discharge temperature over the suction temperature indicates degradation in pump efficiency. It may
occur due to improper operating conditions or health issue of the pump.

Process Performance Overview: Process Performance monitoring view in UAS provides a list of the
asset attributes and their details, including the current value. This list can be used to review and update
asset attribute information, as well as to open an Asset Trend to view more details. It also highlights (in
red color) the attributes if deviates from the high or low limits.

The bearing temperature, vibration and displacement readings are monitored for pump, motor, and
gearbox. The rise in the bearing temperature and vibration indicates improper alignment between
rotating parts. The rise in Lube oil temperature increases the viscosity of the lube oil which reduces the
strength of the oil film on the bearings and may lead to high vibrations.

Lube Oil System

High quality pumps require a form of lubricant to either cool, seal or lubricate key internal components
such as gears, bearings and seals. The lube oil system supplies oil to the pump and driver bearings and
to the gears and couplings. The lube oil is drawn from the reservoir by the pumps and is fed under
pressure through coolers and filters to the bearings.

Tank level: Loss in lube oil tank level can lead to loss of lubrication and pump trip scenario. The reservoir
may be pressurized or vented.

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Supply pressure and temperature: Temperatures and pressures are measured at all important locations
in the system, including temperatures from oil sumps, return lines from bearings, gears and other
mechanical components. Temperatures and pressures are often recorded on the suction and discharge
sides of each compression stage to offer the operator a sense of the health of the system. The readings
can be taken locally or transmitted to a monitoring station. The flow of oil to each bearing is regulated
individually by orifices, particularly important for lubrication points requiring different pressures.

Return temperature: Heat generated by friction in the bearings is transferred to the cooling medium in
the oil coolers. Air-cooled oil coolers may be employed as an alternative to water-cooled oil coolers.

Differential pressure across Filters: Filters clean the lube oil before it reaches the lubrication points and
a differential pressure gauge monitors the degree of fouling (flow restriction) of the filters.

Seal System
The seal oil system supplies the mechanical contact and floating ring seals with an adequate flow of seal
liquid always, correctly ensuring proper function. The oil in the overhead tank is in contact with the
reference gas pressure via a separate line, with a static head providing the required pressure differential.

Tank Level: The oil in the overhead tank compensates for pressure fluctuations and serves as a rundown
supply if pressure is lost. If the level in the tank falls excessively, a level switch shuts down the pump. A
moderate oil temperature is maintained by a constant flow of oil through the overhead tank.

Seal Pressure: The seal oil supply system must be capable of supplying higher seal oil pressure than the
highest possible pump process pressure inboard of the oil seal - which may include settle out, or pump
discharge pressure. The seal pressure at supply and at all important locations of the seal system.

3.2 Energy Monitoring

This Section explains the KPIs to be monitored to optimize the Energy consumption.

Power Deviation: This KPI represents the deviation of Operating power with the expected at current
operating conditions.

% Power Deviation = (OperatingShaftPower-DesignPower)/Design Power*100

Efficiency Deviation: This KPI represents the deviation of Operating efficiency with the expected
efficiency at current operating conditions.

Efficiency Deviation = (Operating efficiency - Expected efficiency)

Degradation Loss: Degradation in a pump can be defined as the pump operating outside of acceptable
operating limits.

Degradation Loss = (Operating Hydraulic Power/Operating Efficiency) - Expected Power.

% Degradation Loss = (Degradation Loss/Electric Power)*100

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Where, Expected Power is the design power which is available from the pump performance curve.

BEP Loss: BEP is the best efficiency point from the pump performance curve. It is a constant value for a
pump.

The amount of losses incurred by operating pump away from BEP value are captured as BEP losses.

BEP Loss = (Expected Efficiency at BEP - Expected Efficiency) *Motor Power*Motor Efficiency.

% BEP Loss = (BEP Loss/Electric Power)*100

Recycle Loss: Recycle loss in a pump can be defined as the loss occurred due to recycle of the operating
fluid.

Recycle loss = (Hydraulic Power – Operating Power) * Operating Efficiency.

Recycle loss % = (Recycle Loss/Electric Power)*100

3.3 Performance Monitoring

The effective utilization of the equipment can be monitored with the help of performance indicators.

Key Performance Indicators

The following indicators help to know the overall performance of the centrifugal pump.

Operating Head
The pressure of the liquid can be stated in terms of meters of head of the liquid column. As in case of
volumetric flow rate, the head generated by the pump for a single point of operation is the same for any
liquid. Depending on the density of the liquid what changes is the reading on the pressure gauge.

The difference between the discharge head and the suction head is termed as Operating Head.

Operating Head H (m) = (Pd-Ps) *10 / ρ

Where, Pd = Discharge pressure (kg/cm2)

Ps = Suction pressure (kg/cm2)

ρ = Specific gravity of the liquid

Expected Head
Expected head is the actual design head which is derived from the pump performance curve at current
volumetric flow rate.

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Head Deviation
% Head Deviation = ((Operating Head-Expected Head)/Expected Head) *100

Hydraulic Power
Power is consumed by a pump to move and increase the pressure of a fluid.

The power requirement of the pump depends on a number of factors including the pump and motor
efficiency, the differential pressure and the fluid density, viscosity and flow rate.

The hydraulic power which is also known as operating or absorbed power, represents the energy
imparted on the fluid being pumped to increase its velocity and pressure.

Hydraulic Power PH (KW) = (Q* ρ*g*H) / (3.6*106)

Where, Q = Volumetric flow in m3/h

ρ = Liquid density in Kg/m3 at pumping temperature.

g = Gravitational acceleration in m/s2

H = Differential Head in m (meters of liquid column)

Operating Shaft Power

Operating Shaft Power:

Operating Shaft Power is the power delivered by the driver at the shaft of the pump.

Operating Shaft Power PS (KW) = PE * ηM

Where, PE – Electrical Power (kW)

ηM = Motor Efficiency (%)

Expected Power
Expected power is the design power which is derived from the pump performance curve at operating
volumetric flow rate.

% Power Deviation = ((Operating Power-Expected Power)/Expected Power) *100

Electric Power
The power delivered to the electric motor connected to pump is called Electrical Power. Increase in
electric power consumption at same load indicates degradation in pump efficiency.

Electric Power is input to the model for pump efficiency calculation. If direct power indication is not
available, then it can be calculated by using current and voltage to motor.

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Electric Power PE (KW) = (√3* V * I * PF)/1000

Where, V = Voltage measured in volts

I = Current measured in ampere

PF = Power Factor

Operating NPSHA
The Net Positive Suction Head available (NPSHa) is the pressure at the pump suction, above the vapor
pressure of the liquid, expressed as head of liquid.

It is the characteristic of Pump Inlet piping, fluid temperature and vapor pressure.

NPSHa (available) must be greater than NPSHr (required) for the pump system to operate without
cavitating and hence trouble free operation of the pump.

NPSHa = Hss-Hfs-Hvp

= P + Z-Hfs-Hvp

where

Hss= Static Suction Head, expressed in metre of Liquid Column (mLC)

= P+Z, if the pump is going to be installed below the free surface of liquid

= P-Z, if the pump is going to be installed above the free surface of liquid

P=Absolute pressure over free surface of liquid at source

Z=Vertical distance between free surface of liquid at source and centerline for horizontal pump

= Vertical distance between free surface of liquid at source and suction eye impeller for vertical pump

Hfs=Friction loss in suction line, expressed in metre of Liquid Column (mLC)

Hvp=vapour pressure of liquid at suction Temperature, expressed in metre of Liquid Column (mLC)

Expected NPSHA
Expected NPSH is the required NPSH which is derived from the pump performance curve at operating
volumetric flow rate.

NPSH Deviation
% NPSH Deviation = ((Operating NPSHa - Expected NPSH)/Expected NPSH) *100

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Operating Efficiency
Pump efficiency is defined as the ratio of water horsepower output from the pump to the shaft
horsepower input for the pump.

Operating Efficiency = (Operating Power/ (Operating Shaft Power))*100

Expected Efficiency
Expected efficiency is the design efficiency which is derived from the pump performance curve at
operating volumetric flow rate.

BEP Efficiency
The Best Efficiency Point (BEP) is defined as the flow at which the pump operates at the highest or
optimum efficiency for a given impeller diameter. When we operate a pump at flows greater than or less
than the flow designated by the BEP, we call this “operating pumps away from the Best Efficiency Point”.

BEP Flow
The Best Efficiency Point (BEP) Flow is defined as the flow at which the pump operates at the highest or
optimum efficiency for a given impeller diameter. When we operate a pump at flows greater than or less
than the flow designated by the BEP, we call this “operating pumps away from the BEP”.

As per the affinity law, model calculates BEP flow at different speed.

Performance Overview
The performance of a centrifugal pump is characterized by two sets of performance curves. The first
curves of DesignHead versus Flow rate. The second curve of DesignEfficiency versus Flow rate. There is
also a provision of curves for NPSHr versus Flow rate and Power versus Flow rate.

UAS facilitates indication of operating points on performance curves. It helps to monitor centrifugal
pump performance against design curves and analyzing upset scenarios.

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Pump Performance Curve
The performance of a centrifugal pump is characterized by two sets of performance curves. The first set
consists of curves of Power versus Flow rate. The second set consists curves of Head versus Flow rate.

UAS facilitates indication of operating points on performance curves. It helps to monitor centrifugal
pump performance against design curves and analyzing upset scenarios.

3.4 Failure Modes

In Uniformance Asset Sentinel, you can configure faults, symptoms, and fault models on pump inputs
and performance output to diagnose the problems early. The fault management can inform operators of
any violations of the nominal pump operating range and deviations from the expected characteristic and
make this data available for further processing through the historian. The fault symptoms or models are
used to:
o Warn against potential damage to pumps under unfavorable operating conditions.
o Provide early warning of damages to the pump.

The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions

o Low pump efficiency: It is determined by means of the deviation of the operating pump efficiency
from the design efficiency.
o Cavitation: It is determined by means of the calculated NPSH value, early warning when a
minimum NPSH reserve is undershot: The minimum NPSH is the design NPSH or user configured
value.

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 o High gas content: It is determined by means of the reduction in delivery height or head.
o Blockage: It is determined on the basis of a limit value for an electrical power being undershot.
o Dry running: It is determined on the basis of a (second, lower) limit value for an electrical power
being undershot.
o Incorrect direction of rotation (the motor was connected incorrectly and rotates in the wrong
direction): It is determined when the delivery height or head falls significantly (> 40%) but with only a
slight deviation (< 20%) of the power characteristic.
o Limit value violation for power values (e.g. electrical overload).
o Deviation of the operating point from the flow characteristic (i.e. reduction in delivery height or
head: indication of high gas content, cavitation, blockage or dry running). This is configured by flow
loss or capacity loss of pump.
o Deviation of the operating point from the power characteristic: It is configured by percent
deviation in power between operating and design values.

The following messages can be generated for maintenance alarms or notifications to indicate
advanced pump wear

Pump wear is indicated by a long standing (for hours or days) reduction in the delivery height or head
(high gas content and cavitation can also have the same effect, but this should only be temporary).

The “Deviation from flow characteristic” alarm is therefore integrated over time, by means of an
operating hours counter and a maintenance alarm or notification. The “Pump worn out” is triggered
when a particular limit (example three days) is reached.

Another useful diagnostic alarm is generated when a particular number of operating hours for the pump
in cavitation mode is reached. For this purpose, a second operating hours counter has to be activated
when Operating NPSH < design NPSH. In this case, an alarm “Pump damage due to cavitation” is
triggered after just a few hours in cavitation.

Below table illustrates the list of faults and symptoms configured for a pump to identify possible
anomalies that affects the performance or health of a pump.

Fault Category Fault Name Associated Symptoms

Performance Parameter Deviation High Efficiency Deviation High

Shaft Power Deviation High
Performance Head Deviation High
Performance Parameter Deviation High
NPSH Deviation High
Low Suction Flow
High Suction Flow Warning
Low Suction Flow Warning
Health Cavitation Warning
Net Positive Suction Head available is Low
Low Suction Pressure

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 Fault Category Fault Name Associated Symptoms

Pump Inlet Flow Low

Performance Impeller Degradation
Pump Operating Head Low
Running Outside Preferred BEP Region
Performance Running Outside BEP Region
Running Outside Allowable BEP Region

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

3.5 Configuration
As described in previous sections, centrifugal pump performance monitoring model is used to:
o Calculate the current operating point data such as head, power consumed, and NPSH. The
calculation is performed based on the inputs received from DCS/Historian or based on the
configured model parameters.
o Interpolate or extrapolate the design data for the current operating FlowRate from the
Manufacturer performance curve.

The calculation model to perform as expected, it requires some inputs are to be feed into the model. The
centrifugal pump model input data consists of measured data and static data. Measured input data is

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supplied to the model from DCS or Historian by tag mapping. This section describes the list of input and
output attributes and its properties.

Model Input data

Attribut
S Monitorin
e
N Attribute Description Units g Source
Categor
o Category
y

Current (Required Input if Ampere Field Input/

1 Current Electrical Power is not given) s Dynamic Process Constant
DischargePressu Discharge Pressure (Required
2 re Input) barg Dynamic Process Field Input
3 FlowRate Volume Flow Rate (Required Input) m3/hr Dynamic Process Field Input
RecirculationFlo
4 w RecirculationFlow(Input) m3/hr Dynamic Process Field Input
5 Speed Measured Speed (Input) rpm Dynamic Process Field Input
6 SuctionPressure Suction Pressure (Required Input) barg Dynamic Process Field Input
7 Temperature Temperature C Dynamic Process Field Input
Vapour Pressure (Required Input if
8 VapourPressure Property Data is not given) bara Dynamic Process Field Input
Voltage (Required Input if
10 Voltage Electrical Power is not given) V Dynamic Process Field Input
Lab
Measurement
Thermo / Interpolated
11 Density Density (Overall) kg/m3 Dynamic Properties from Curve
Temperature,Density,VapourPress Tabular Thermo
12 PropertyData ure Array Static Properties Constant

Electrical Power (Required Input if Field Input/

13 ElectricalPower Voltage and Current are not given) kw Dynamic Process Calculated
14 MechEfficiency Mechanical Efficiency (Input) Static Design Constant
15 PowerFactor Power Factor (Input) Static Design Constant

NOTE
The Electrical Power or power consumed by pump must be calculated with custom calculation
expression or must be mapped to power measurement data collected from DCS or historian.

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Model Output data
S Attribute Description Units Attribute Monitoring Source
No Category Category

1 DesignEff Efficiency at current flow rate % Dynamic Design Calculated

from curve data (Output)

2 DesignEfficiencyatBEP DesignEfficiencyatBEP % Dynamic Design Calculated

3 DesignHead Actual Head at current flow rate m Dynamic Design Calculated

(Output)

4 DesignNPSH NPSH at current flow rate from m Dynamic Design Calculated

curve data (Output)

5 DesignPower Power at current flow rate from kW Dynamic Design Calculated

curve data (Output)

6 DeviationHead Percent Deviation in Head % Dynamic Performance Calculated

between Operating and Design
values (Output)

7 DeviationNPSH Percent Deviation in NPSH % Dynamic Performance Calculated

between Operating and Design
values (Output)

8 OperatingEff Operating Efficiency (Output) % Dynamic Performance Calculated

9 OperatingHead Operating Head (Output) m Dynamic Performance Calculated

10 OperatingNPSH NPSHA - Net Positive Suction m Dynamic Performance Calculated

Head Available (Output)

11 OperatingPower Operating Power (Output) kW Dynamic Performance Calculated

Configuring a Centrifugal Pump Asset in Uniformance Asset

Sentinel
Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter
Centrifugal Pump.

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To configure Asset Performance attributes
1. On the Asset Attribute Configuration pane, click the PerformanceData attribute.
2. The details of the attribute are displayed in the Edit selected asset attribute section. By default all the
details are disabled.

3. Click the icon.

The Array Data button is enabled.

4. Click Array Data.

The PerformanceData dialog box is displayed.

5. Enter values for FlowRate, Head, Efficiency, and Power.

6. Click OK.
7. Click Save to save the changes made to the attribute.
8. To configure an array of data (PropertyData)
9. On the Asset Attribute Configuration pane, click the PropertyData attribute.
10. The details of the attribute are displayed in the Edit selected asset attribute section. By default all the
details are disabled.

11. Click the icon.

12. The Array Data button is enabled.
13. Click Array Data.
14. The PropertyData dialog box is displayed.

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15. Enter values for Temperature, Density, and VapourPressure.
16. Click OK.
17. Click Save to save the changes made to the attribute.

Alternatively, see “Configuring Asset Attributes” in the Uniformance Asset Sentinel Configuration Guide
can be followed to configure Asset Performance attributes.

Refer to the following procedures:

o To configure asset connection attributes.
o To map a dynamic attribute to the datasource tags.
o To set the attribute properties for the Attribute Viewer and Performance Overview.
o To manually update asset attribute information.

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 Centrifugal Compressor
Monitoring

Compressors are used to transport the gases and to increase pressure of gases in process plants, power
plants, and other industries. Compressor performance has a significant impact on overall plant
performance in terms of energy usage, efficiency, and throughput.

Centrifugal compressors are also known as turbo-compressors belong to the roto-dynamic type of
compressors. In these compressors, the required pressure rise takes place due to the continuous
conversion of angular momentum imparted to the gas vapor by a high-speed impeller into static
pressure. As shown in figure below, low-pressure gas enters the compressor through the eye of the
impeller. The impeller consists of a number of blades, which form flow passages for gas. From the eye,
the gas enters the flow passages formed by the impeller blades, which rotate at very high speed. As the
gas flows through the blade passages towards the tip of the impeller, it gains momentum and its static
pressure also increases. From the tip of the impeller, the gas flows into a stationary diffuser. In the
diffuser, the gas is decelerated and as a result the dynamic pressure drop is converted into static
pressure rise, thus increasing the static pressure further. The vapor from the diffuser enters the volute
casing where further conversion of velocity into static pressure takes place due to the divergent shape of
the volute. Finally, the pressurized gas leaves the compressor from the volute casing.

Monitoring basic machine health data in addition to compressor operating conditions helps to maintain
reliable operations of a compressor. There are three areas that helps to monitor compressor
performance to increase the availability and decrease the energy costs.
o Process and condition monitoring
o Energy monitoring
o Performance and Health monitoring

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Individually, each of these important indicators collectively, they provide a complete picture as to the
actual condition of the Compressor. This document explains centrifugal Compressor monitoring
philosophy for process, performance, energy and health parameters and their importance.

Item Type
Category Equipment
Equipment Class Compressor
Equipment Type Centrifugal Compressor (Constant
speed/Variable Speed)

Following are the types of centrifugal compressors which are supported in this UAS template:
o Centrifugal Compressor-Constant speed
o Centrifugal Compressor-Variable Speed

4.1 Process Performance Monitoring

The following measured parameters are monitored as they have impact on performance and health of
compressor, if not maintained in operating range.

Suction Temperature: Increase in suction temperature reduces the feed density which increases
volumetric flow rate to be compressed for delivery of same amount of discharge mass. At the same time,
lower suction temperature may lead to condensation of vapor feed which can lead to increase in
vibration and trip scenario.

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Suction Pressure: Decrease in suction Pressure indicates the low feed to compressor which can lead to
critical asset health condition like surging, also a lower suction pressure may also increase the pressure
ratio across the compressor if the discharge pressure is controlled, which can lead to surging.

Discharge Temperature: Higher discharge temperature indicates the upset in overall operations of
equipment and may lead to trip scenario. Example, it may be because of low coolant flow, high coolant
temperature, high bearing temperatures, or drop in efficiency, etc.

Discharge Pressure: Higher discharge pressure indicates the upset in overall operations of equipment
and may lead to trip scenario. It may be due to some different reasons like, obstacles in downstream
operations, aftercooler is fouled, etc.

Speed: It is direct indication of load on compressor.

Antisurge Valve Opening and flow: Surge is an unstable and undesirable operating condition of the
compressor, occurring when the flow through it is less than surge flow. This causes a momentary flow
reversal, reducing line pressure and causing erratic behavior. For ensuring safety of equipment, an
antisurge controller maintains flow near the control line. Additional circulation beyond the control line is
operational loss due to excess compression.

The bearing temperature, vibration and displacement readings are monitored for Compressor, motor,
and gearbox. The rise in the bearing temperature and vibration indicates improper alignment between
rotating parts. The rise in Lube oil temperature increases the viscosity of the lube oil which reduces the
strength of the oil film on the bearings and may lead to high vibrations.

Process Performance Overview: Process Performance monitoring view in UAS provides a list of the
asset attributes and their details, including the current value. This list can be used to review and update
asset attribute information, as well as to open an Asset Trend to view more details. It also highlights (in
red color) the attributes if deviates from the high or low limits.

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Lube Oil System
Nearly all compressors require a form of lubricant to either cool, seal or lubricate key internal
components such as gears, bearings and seals. The lube oil system supplies oil to the compressor and
driver bearings and to the gears and couplings.

Tank level: Loss in lube oil tank level can lead to loss of lubrication and compressor trip scenario. The
reservoir may be pressurized or vented.

Supply pressure and temperature: Temperatures and pressures are measured at all important locations
in the system, including temperatures from oil sumps, return lines from bearings, gears and other
mechanical components. Temperatures and pressures are often recorded on the suction and discharge
sides of each compression stage to offer the operator a sense of the health of the system. The readings
can be taken locally or transmitted to a monitoring station. The flow of oil to each bearing is regulated
individually by orifices, particularly important for lubrication points requiring different pressures.

Return temperature: Heat generated by friction in the bearings is transferred to the cooling medium in
the oil coolers. Air-cooled oil coolers may be employed as an alternative to water-cooled oil coolers.

Differential pressure across Filters: Filters clean the lube oil before it reaches the lubrication points and a
differential pressure gauge monitors the degree of fouling (flow restriction) of the filters.

Seal System
The seal oil system supplies the mechanical contact and floating ring seals with an adequate flow of seal
liquid at all times, correctly ensuring proper function. The oil in the overhead tank is in contact with the
reference gas pressure via a separate line, with a static head providing the required pressure differential.

Tank Level: The oil in the overhead tank compensates for pressure fluctuations and serves as a rundown
supply if pressure is lost. If the level in the tank falls excessively, a level switch shuts down the
compressor. A moderate oil temperature is maintained by a constant flow of oil through the overhead
tank.

Seal Pressure: The seal oil supply system must be capable of supplying higher seal oil pressure than the
highest possible compressor process pressure inboard of the oil seal - which may include settle out, or
compressor discharge pressure. The seal pressure at supply and at all important locations of the seal
system.

4.2 Energy Monitoring

This section explains the KPIs to be monitored to optimize the Energy consumption.

Degradation losses: This KPI represents the additional power consumed due to excessive power utilized
by the compressor when compressor is running at low efficiency.

Degradation losses= (DeviationPolyEff/ExpectedPolyEff)*OperatingShaftPower

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Operational losses: This KPI represents the additional power consumed due to excessive power utilized
by the compressor when compressor is running with recirculation.

Operational losses= (AntiSurge_Flow/Inlet1_VolumeFlowRate)*OperatingShaftPower

Power deviation: This KPI represents the deviation of Operating Power with Expected Power at current
operating conditions.

Power Deviation %= (OperatingShaftPower-ExpectedShaftPower)/ExpectedShaftPower*100

Degradation losses in $ value: This KPI represents the additional expense incurred due to excessive
power utilized by the compressor when compressor is running at low efficiency.

Degradation losses in $ value= Degradation Loss (in KW) *Energy_Cost_per_KW

Operational losses in $ value: This KPI represents the additional expense incurred due to excessive
power utilized by the compressor when compressor is running with recirculation.

Operational losses in $ value=Operational Loss (in KW) *Energy_Cost_per_KW

Degradation and Operational loss KPIs are aggregated for the calendar date to facilitate daily basis
analysis.

4.3 Performance Monitoring

The effective utilization of the equipment can be monitored with the help of performance indicators.

Key Performance Indicators

The following indicators help us to know overall performance of the compressor.

Operating Polytropic Efficiency

Polytropic Efficiency is a process whereby compression is divided into numerous small steps with the
steps contain similar isentropic efficiency. Operating Polytropic efficiency is defined as the ratio of the
Operating Polytropic Head(m) to the Operating Head(m).

Operating Polytropic Efficiency (%)=(Operating Polytropic head/ Operating Head)*100

𝐻𝐻𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃
𝜂𝜂𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 = x 100 Where,
𝐻𝐻𝑀𝑀

Operating Head (m) = 𝐻𝐻𝑀𝑀 = Discharge enthalpy (kJ/kg) –Suction enthalpy (kJ/kg)

9.81
𝐻𝐻2𝑀𝑀 −𝐻𝐻1
𝐻𝐻𝑀𝑀 =
9.81

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Where, 𝐻𝐻2𝑀𝑀 (kJ/kg) = Discharge enthalpy at Operating discharge temperature and pressure. This can be
calculated using the thermo module the fluid discharge conditions T2 and P2.

𝐻𝐻1 (kJ/kg) = Suction enthalpy at Operating suction temperature and pressure. This can be calculated
using the thermo module the fluid suction conditions T1 and P1.
1
1545 𝑛𝑛1 𝑇𝑇1 𝑍𝑍1 𝑃𝑃 𝑛𝑛1
Operating Polytropic Head (m) =𝐻𝐻𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 = �� 2 � − 1�
𝑀𝑀𝐺𝐺 𝑃𝑃1

𝑃𝑃
𝐿𝐿𝐿𝐿𝐿𝐿� 2 �
𝑃𝑃1
𝑛𝑛1 = 𝑇𝑇2 𝑍𝑍2
𝐿𝐿𝐿𝐿𝐿𝐿� �
𝑇𝑇1 𝑍𝑍1

P1 = Pressure at suction (barg)

P2 = Pressure at discharge (barg)

Z1 = Compressibility at suction

T1 = Temperature at suction (Deg C)

MG = Gas molecular weight (kg/kmole)

Expected Polytropic efficiency

Expected Polytropic efficiency is derived from the compressor performance curve at current volumetric
flow rate and speed.

Expected polytropic efficiency (%) = 𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑑𝑑𝑑𝑑𝑡𝑡𝑎𝑎

𝜂𝜂𝐸𝐸= 𝜂𝜂𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃

Efficiency Deviation
This KPI represents the deviation of Operating efficiency with expected Efficiency at current operating
conditions. It indicates excess power consumed by compressor.
% Efficiency Deviation = ((Operating Efficiency-Expected Efficiency)/Expected Efficiency) *100

Operating Head
Operating head is defined as the difference between the operating discharge enthalpy and the operating
suction enthalpy.
Operating Head (m) = Discharge enthalpy (kJ/kg) –Suction enthalpy (kJ/kg)
9.81

𝐻𝐻2𝑀𝑀 −𝐻𝐻1
𝐻𝐻𝑀𝑀 =
9.81

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Where, 𝐻𝐻2𝑀𝑀 (kJ/kg) = Discharge enthalpy at Operating discharge temperature and pressure. This can be
calculated using the thermo module the fluid discharge conditions T2 and P2.

𝐻𝐻1 (kJ/kg) = Suction enthalpy at Operating suction temperature and pressure. This can be calculated
using the thermo module the fluid discharge conditions T2 and P2.

Expected Head
Expected head (m) is defined as the ratio of the expected polytropic head to expected polytropic
efficiency. Get Expected polytropic head from map data at expected polytropic efficiency and expected
speed from performance curves data. This will be equal to measured isentropic head. Use the corrected
speed and head in the interpolation.

HPolyE (m) = Expected polytropic head from Performance Curve

Expected Head = Expected polytropic head (m) / Expected polytropic efficiency (%)

𝐻𝐻𝐸𝐸 = 𝐻𝐻𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 /𝜂𝜂𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃

Head Deviation
This KPI represents the deviation of Operating head with Design Head at current operating conditions.

% Head Deviation = ((Operating Head-Expected Head)/Expected Head) *100

Operating Power
Operating power (kW) is defined as the ratio of the operating head to the operating efficiency.

Ho × vaporflow
Po =
ηo × 3600 × MW

Where, Ho = Operating Head (m)

MW = Gas Molecular Weight (kg/kmol)

ηo = Operating Efficiency (%)

Vaporflow is in Kmol/hr

Expected Power
Expected power is defined as the ratio of the Expected head to the Expected efficiency.

He × vaporflow
Pe =
ηe × 3600 × MW

Where, He = Expected Head

MW = Gas Molecular Weight (kg/kmol)

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ηe = Expected Efficiency (%)

Vaporflow is in Kmol/hr

Power Deviation
This KPI represents the deviation of Operating Power with Design Power at current operating conditions.

% Power Deviation = ((Operating Power-Expected Power)/Expected Power) *100

Index Calculations
Fouling Index = (Operating Shaft Power – Design Shaft Power) / Operating Shaft Power

Here, Power is in kW

Energy Index = Abs(Percent Deviation Shaft Power) / 100;

Performance Index = Operating Poly Eff (%) / 100

Capacity losses
CapacityLoss = ((InVolumeFlowRate / ExpectedVolumeFlow) - 1) * 100;

Here, expected volumetric flow rate is derived from performance curve at measured speed and pressure
ratio.

Antisurge Valve opening duration

It indicates total duration (min) for which Antisurge valve is opened (24 hrs. basis).

Performance Overview
Equipment Key Performance Indicators (KPIs) view in UAS provides a list of KPIs and their details,
including the current value. This list can be used to review and update asset attribute information, as
well as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if
deviates from the high or low limits.

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Compressor Performance Curve
The performance of a variable speed, centrifugal compressor is characterized by two sets of curves that
are typically supplied by the compressor manufacturer. The first set consists of curves of polytropic head
versus volumetric suction flow, each curve corresponding to a different operating (rotational) speed, all
at the same suction conditions. The second set consists of corresponding curves for power. These sets
of curves, referred to as performance maps, are used in the flow-pressure relationship for the centrifugal
compressor. Inlet guide vanes and variable speed performance curves are available for respective
models.

UAS facilitates indication of operating points on performance curves. It helps to monitor compressor
performance against design curves and analyzing upset scenarios. This also helps to visualize the
deviation of current operating flow with flow at optimum efficiency point.

4.4 Failure Modes

In UAS, a fault model is built to identify possible anomalies that affects the performance or health of a
Compressor. The fault management can inform operators of any violations of the nominal compressor
operating range and deviations from the expected characteristic and make this data available for further
processing through the historian. The fault symptoms or models are used to:
o Warn against potential damage to Compressor under unfavorable operating conditions.
o Provide early warning of damages to the Compressor.

The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions

o Determine surge or choking: Surge occurs if the flow of the gas through the compressor is less.
Choking is a condition where the flow is more than maximum flow or stone wall flow. Surge is

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Model Library Guide 42
 determined by configuring fault models for flow rate less than minimum limit. Choking is determined
by configuring fault models for flow rate more than maximum limit.
o Deviation of the operating point from the flow characteristic (reduction in delivery height or
head: indication of low compression ratio, blockage, or dry running): is configured by flow loss or
capacity loss of compressor.
o Deviation of the operating point from the power characteristic: It is configured by percent
deviation in power between operating and design values.
o Low compressor efficiency: It is determined by means of the deviation of the current compressor
efficiency from the efficiency characteristic.
o Gas leakage: It is detected by checking the material balance.
o Compressor damage or insufficient lubrication: It is detected sometime by observing the noise
levels, high discharge temperature, and high speed.
o Fouling: It occurs due to deposition of material on the compressor blades or impellers, which
reduces the efficiency and throughput. The output includes compressor fouling fraction that sums
the effects of the degradation of air flow and compressor efficiency on power output. At new and
clean conditions, the fouling fraction is zero. As the compressor becomes fouled, both its efficiency
and the inlet air flow decreases, which results in a negative fouling fraction.

Below table illustrates the list of faults and symptoms configured for a Compressor.
Fault
Fault Name Associated Symptoms
Category
Discharge Temperature High
Suction Temperature High
Performance Performance Degradation Warning Efficiency Deviation High
Performance Index Low
Driver Load High
Discharge Pressure High
Capacity Loss High
Health Health Degradation Warning Flow Outside Stonewall/ Chocking
Flow Outside Surge Line
Surge Margin Low
Energy Consumption High
Energy Energy Consumption High
Head Deviation High

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

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4.5 Configuration
As described in previous sections, centrifugal compressor performance monitoring model is used to:
o Calculate the current operating point data such as head, power consumed and efficiency. The
calculation is performed based on the inputs received from DCS/Historian or based on the
configured model parameters.
o Interpolate or extrapolate the design data for the current operating FlowRate from the
Manufacturer performance curve.

The calculation model to perform as expected, it requires some inputs are to be feed into the model. The
centrifugal Compressor model input data consists of measured data and static data. Measured input
data is supplied to the model from DCS or Historian by tag mapping. This section describes the list of
input and output attributes and its properties.

Model Input data

S Attribute Monitoring
Attribute Description Units Source
no Category Category

Inlet Stream 1
Pressure (Required
1 Inlet Pressure Input) barg Dynamic Process Field Input
Inlet Stream 1
Inlet Temperature
2 Temperature (Required Input) deg C Dynamic Process Field Input

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 S Attribute Monitoring
Attribute Description Units Source
no Category Category

Inlet Stream 1 Volume

Inlet Volume Flow Rate (Required
3 Flow Rate Input) m3/hr Dynamic Process Field Input
Outlet Stream 1
Outlet Pressure (Required
4 Pressure Input) barg Dynamic Process Field Input
Outlet Outlet Stream 1
5 Temperature Temperature (Input) deg C Dynamic Process Field Input
Running Running Status of
6 Status Asset (Input) Dynamic Process Field Input
Measured Speed
7 Speed (Input) rpm Dynamic Process Field Input
Constant
from
Impeller Impeller Manufacture
8 Diameter Diameter(Input) m Static Design r datasheet
Constant
from
GearBox Gear Box Efficiency Manufacture
9 Efficiency (Input) % Static Design r datasheet
Constant
from
Gear Ratio of Asset Manufacture
10 Gear Ratio (Input) Static Design r datasheet
Constant
from
Guide Vane Inlet Guide Vane Manufacture
11 Position Position(Optional) % Dynamic Design r datasheet
Mechanical Mechanical Efficiency
12 Efficiency (Input) % Static Design Constant
Ref Reference
Compressibilit Compressibility
13 y (Input) Static Design Constant
Compression
14 Ref Exponent exponent(Input) Static Design Constant
Ref Molecular Reference Molecular
15 Weight Weight (Input) Static Design Constant
Reference Pressure
16 Ref Pressure (Input) bara Static Design Constant
Ref Reference
17 Temperature Temperature (Input) deg C Static Design Constant
StoneWall StoneWall Line Flow Embedded
18 Line Flow Rate Rate m3/hr Dynamic Design Model

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 S Attribute Monitoring
Attribute Description Units Source
no Category Category

Surge Line Embedded

19 Flow Rate Surge Line Flow Rate m3/hr Dynamic Design Model

Note: The Uniformance Asset Sentinel process and equipment monitoring models require
thermodynamic properties such as enthalpy, entropy, density, and specific heat to be calculated.

There are two options available to compute thermodynamic properties:

o Native Uniformance Asset Sentinel Thermodynamic models
o Linked UniSim Thermodynamic models

For evaluating gas properties for centrifugal compressor inlet and outlet streams, please refer the
procedure for configuring stream assets.

Model Output data

Unit Attribute Monitoring

S No Attribute Description Source
s Category Category

OperatingPo Operating Power

1 wer (Output) kW Dynamic Performance Calculated
Operating Operating Gas
2 Gas Power Power (Output) kW Dynamic Performance Calculated
Operating
Poly Operating Polytropic
3 Efficiency Efficiency (Output) % Dynamic Performance Calculated
Operating
Polytropic Operating Polytropic
4 Head Head (Output) m Dynamic Performance Calculated
Operating Operating Shaft
5 Shaft Power Power (Output) kW Dynamic Performance Calculated
Expected Gas Power
Expected at current flow rate
6 Gas Power (Output) kW Dynamic Design Calculated
Expected Expected Guide Calculated
Guide Vane vane position for
7 Position current flow % Dynamic Design
Expected Head at Calculated
Expected current flow rate
8 Head (Output) m Dynamic Design
Expected Polytropic Efficiency Calculated
Poly from curve data
9 Efficiency (Output) % Dynamic Design

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 Unit Attribute Monitoring
S No Attribute Description Source
s Category Category

Expected Shaft Calculated

Power (Output) at
Expected current flow rate
10 Shaft Power (Output) kW Dynamic Design
Expected Expected Speed for Calculated
11 Speed current flow(Output) rpm Dynamic Design
Expected Flow from Calculated
Expected Performance Curve m3/
12 Volume Flow (Output) hr Dynamic Design
Table 1 Compressor Model Outputs

Configuring a Centrifugal Compressor Asset in Uniformance

Asset Sentinel
To configure a centrifugal compressor asset with performance model

Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter
Centrifugal-VariableSpeed V2 to configure Centrifugal Compressor.

To configure Asset Performance attributes

1. On the Asset Attribute Configuration pane, click the PerformanceData attribute.
2. The details of the attribute are displayed in the Edit selected asset attribute section. By default all the
details are disabled.

3. Click the icon.

The Array Data button is enabled.

4. Click Tabular Data.

The PolyPerformanceData dialog box is displayed.

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5. Enter values for Speed, Flowrate, Operating Head, Operating poly efficiency and pressure ratio from
compressor performance curve.
6. Click OK.
7. Click Save to save the changes made to the attribute.
8. Click Save to save the changes made to the attributes.

Alternatively, see “Configuring Asset Attributes” in the Uniformance Asset Sentinel Configuration Guide
can be followed to configure Asset Performance attributes.

Refer to the following procedures:

o To configure asset connection attributes.
o To map a dynamic attribute to the datasource tags.
o To set the attribute properties for the Attribute Viewer and Performance Overview.
o To manually update asset attribute information.

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 AC Motor Monitoring

An AC motor is an electric motor driven by an alternating current. The AC motor commonly

consists of two basic parts, an outside stator having coils supplied with alternating current to produce a
rotating magnetic field, and an inside rotor attached to the output shaft producing a second rotating
magnetic field.

As the AC Motor used as subsystem for many industrial equipment to operate as expected, it is
important to monitor the health and performance of an AC Motor to increase availability. Monitoring
basic machine health data in addition to AC Motor operating conditions helps to maintain reliable
operations of an AC Motor. There are three areas that helps to monitor an AC Motor performance to
increase the availability.
o Process and condition monitoring
o Performance and Health monitoring

This document explains AC motor monitoring philosophy for process, performance, energy and health
parameters and their importance.
Item Type
Category Equipment
Equipment Class Motor
Equipment Type AS_Motor_AC

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5.1 Process Performance Monitoring
The following measured parameters are monitored as they have impact on performance and health of
AC Motor, if not maintained in operating range.

Measured Voltage (V): When a motor is operated at reduced voltage, even within the allowable 10%
limit, the motor will draw increased current to produce the torque requirements imposed by the load.
This causes an increase in both stator and rotor resistance losses with subsequent increased heating at
rated horsepower load or service factor operation. Operating a motor at the outer limits of its voltage
requirements reduces its efficiency and causes premature failure. Whereas increase in voltage,
magnetizing current increases by an exponential function. Depending upon design of the motor,
saturation of the core iron will occur and overheating will result. At about 10% to 15% above the motor’s
design voltage (overvoltage), both efficiency and power factor significantly decrease for standard
efficiency motors, while the full-load slip decreases.

Measured Current (Amps): An increase in current is a danger to the motor only if that current
exceeds the motor's nameplate current rating. When amps go above the nameplate rating, heat begins
to build up in the motor. The more heat and the longer the exposure to it, the more damage to the motor.
Whereas decreasing in current than require result in decrease efficiency of equipment.

Measured Power (kW): To drive a fixed mechanical load connected to the shaft, a motor must draw a
fixed amount of power from the line. Power is directly impact rotational speed and torque. As more load
is applied the motor draws more current, which increases torque. However, as power increase the
speed of motor increase. Fluctuation in power impact efficiency and operation of equipment.

Process Performance Overview: Process Performance monitoring view in UAS provides a list of the
asset attributes and their details, including the current value. This list can be used to review and update
asset attribute information, as well as to open an Asset Trend to view more details. It also highlights (in
red color) the attributes if deviates from the high or low limits.

5.2 Performance Monitoring

The effective utilization of the equipment can be monitored with the help of performance indicators.

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Key Performance Indicators
The following indicators help us to know overall performance of the AC Motor.

Motor Efficiency
Motor Efficiency of AC motors is calculated as “Percentage of Actual Power Output / Actual Power
Input”.

Motor efficiency = (Actual Power Output / Actual Power Input) *100

Higher the efficiency, better the motor. For ideal motor, the efficiency is 100%. However, efficiency
cannot be more than 100%.

Actual Power Input is calculated as,

Pi = (V x I x PF x √3)/1000

Where:

Pi = Three-phase power in kW

V = RMS voltage, mean line-to-line of 3 phases

I = RMS current, mean of 3 phases

PF = Power factor as a decimal

Actual power output = Shaft power of equipment (Power transmitted by motor to shaft)

Expected Efficiency: Expected Efficiency of AC motors is calculated using following empirical equation

Expected efficiency = A*ML^2 + B*ML + ML

Where,

ML= Motor Load

A = -0.00125

B=0.175

Motor Load

This is the ratio of Actual Input Power to Rated Power (Nameplate Power).
Actual Input Power is calculated as,

Pi = (V x I x PF x √3)/ 1000

Where:

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Pi = Three-phase power in kW

V = RMS voltage, mean line-to-line of 3 phases

I = RMS current, mean of 3 phases

PF = Power factor as a decimal

Rated power is calculated as,

Pir = (hp x 0.7457)/ηfl

Where:

Pir = Input power at full-rated load in kW

hp = Nameplate rated horsepower

ηfl = Efficiency at full-rated load

Electric motor datasheet usually provides the efficiency and power factor at full load and at various part
loads (for example 50%,75%).

Performance Overview
Equipment Key Performance Indicators (KPIs) view in UAS provides a list of KPIs and their details,
including the current value. This list can be used to review and update asset attribute information, as well
as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if deviates
from the high or low limits.

5.3 Failure Modes

In UAS, a fault model is built to identify possible anomalies that affects the performance or health of an
AC Motor. The fault management can inform operators of any violations of the nominal Motor operating
range and deviations from the expected characteristic and make this data available for further
processing through the historian.

The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions

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 o Low Efficiency: Occurs mainly due to improper load conditions. At low load, the frictional losses
cause low efficiency of the motor. At high load, as the load torque increases the speed of the motor
decreases which will impact the motor efficiency. Hence, it is required to optimize the load on motor
to achieve maximum efficiency.
o Overheating: Occurs due to excessive load on motor which will cause damage to the motor. It is
important to monitor the housing and winding temperatures to maintain the health of the motor.

Below table illustrates the list of faults and symptoms configured for an AC Motor.

Fault
Fault Name Associated Symptoms
Category
High Load
Performance Performance Degradation Warning Low Load
Low Efficiency
Health Health Degradation Warning High Housing Temperature

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

5.4 Configuration
The calculation model to perform as expected, it requires some inputs are to be feed into the model. The
AC Motor model input data consists of measured data and static data. Measured input data is supplied
to the model from DCS or Historian by tag mapping. This section describes the list of input and output
attributes and its properties.

Model Input data

S Attribute Monitoring
Attribute Description Units Source
No Category Category

Motor Active Motor Active

1 Power Power(Input) kW Dynamic Process Field Input
2 Motor Current Motor Current (Input) Amperes Dynamic Process Field Input

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 S Attribute Monitoring
Attribute Description Units Source
No Category Category

Motor Power Motor Power Factor

3 Factor (Input) Dynamic Process Field Input
Motor
Housing Motor Housing
4 Temperature Temperature (Input) deg C Dynamic Process Field Input
5 Motor Voltage Motor Voltage (Input) V Dynamic Process Field Input
Constant A (Expected
6 Constant A efficiency) Static Design Constant
Constant B (Expected Constant
7 Constant B Efficiency) Static Design
Constant C (Expected Constant
8 Constant C Efficiency) Static Design
9 Rated Power Rated Power(Input) Static Design Constant

Model Output data

S Attribute Monitoring
Attribute Description Units Source
No Category Category

Motor Actual Motor Actual

1 Efficiency Efficiency (Output) % Dynamic Performance Calculated

Motor
Calculated Motor Calculated
2 Power Power (Output) kW Dynamic Performance Calculated

Motor Expected Motor Expected

3 Efficiency Efficiency (Output) % Dynamic Performance Calculated

4 Motor Load Motor Load (Output) % Dynamic Performance Calculated

Configuring an AC Motor in Uniformance Asset Sentinel

To configure an AC Motor asset

Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter
AC_Motor_01.

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Model Library Guide 54
Refer to the following procedures:
o To configure asset connection attributes.
o To map a dynamic attribute to the datasource tags.
o To set the attribute properties for the Attribute Viewer and Performance Overview.
o To manually update asset attribute information.

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 DC Motor Monitoring

A motor is a machine that converts electrical energy into mechanical energy. When a DC machine is
loaded either as a motor or generator, the rotor conductors carry current. Since the conductors lie in the
magnetic field created in the air gap, they experience a force. Torque (turning effect) is developed on the
rotor and the rotor starts rotating. When the machine operates as a motor the torque is transferred to the
shaft of the rotor and drives the mechanical load.

Monitoring basic machine health data in addition to DC Motor operating conditions helps to maintain
reliable operations of an DC Motor. There are two areas that helps to monitor DC Motor performance to
increase the availability and decrease the energy costs.
o Process and condition monitoring
o Performance and Health monitoring

This document explains DC Motor monitoring philosophy for process, performance, energy and health
parameters and their importance.

Item Type
Category Equipment
Equipment Class Motor
Equipment Type AS_Motor_DC

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6.1 Process Performance Monitoring
The following measured parameters are monitored as they have impact on performance and health of
DC Motor, if not maintained in operating range.

Measured Voltage (V): When a motor is operated at reduced voltage, even within the allowable 10%
limit, the motor will draw increased current to produce the torque requirements imposed by the load.
This causes an increase in both stator and rotor resistance losses with subsequent increased heating at
rated horsepower load or service factor operation. Operating a motor at the outer limits of its voltage
requirements reduces its efficiency and causes premature failure. Whereas increase in voltage,
magnetizing current increases by an exponential function. Depending upon design of the motor,
saturation of the core iron will occur, and overheating will result. At about 10% to 15% above the motor’s
design voltage (overvoltage), both efficiency and power factor significantly decrease for standard
efficiency motors, while the full-load slip decreases.

Measured Current (Amps): An increase in current is a danger to the motor only if that current
exceeds the motor's nameplate current rating. When amps go above the nameplate rating, heat begins
to build up in the motor. The more heat and the longer the exposure to it, the more damage to the motor.
Whereas decreasing in current than require result in decrease efficiency of equipment.

Measured Power (KW): To drive a fixed mechanical load connected to the shaft, a motor must draw a
fixed amount of power from the line. Power is directly impact rotational speed and torque. As more load
is applied the motor draws more current, which increases torque. However, as power increase the
speed of motor increase. Fluctuation in power impact efficiency and operation of equipment.

Process Performance Overview: Process Performance monitoring view in UAS provides a list of the
asset attributes and their details, including the current value. This list can be used to review and update
asset attribute information, as well as to open an Asset Trend to view more details. It also highlights (in
red color) the attributes if deviates from the high or low limits.

6.2 Performance Monitoring

The effective utilization of the equipment can be monitored with the help of performance indicators.

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Key Performance Indicators
The following indicators help us to know overall performance of the DC Motor.

Motor Efficiency
Motor Efficiency of DC motors is calculated as “Percentage of Actual Power Output / Actual Power
Input”.

Motor efficiency = (Actual Power Output / Actual Power Input) *100

Higher the efficiency, better the motor. For ideal motor, the efficiency is 100%. However, efficiency
cannot be more than 100%.

Actual Power Input is calculated as,

Pi = (V x I x PF x √3)/1000

Where:

Pi = Three-phase power in kW

V = RMS voltage, mean line-to-line of 3 phases

I = RMS current, mean of 3 phases

PF = Power factor as a decimal

Actual power output = Shaft power of equipment (Power transmitted by motor to shaft)

Expected Efficiency: Expected Efficiency of DC motors is calculated using following empirical equation

Expected efficiency = A*ML^2 + B*ML + ML

Where,

ML= Motor Load

A = -0.00125

B=0.175

Motor Load
This is the ratio of Actual Input Power to Rated Power (Nameplate Power).

Actual Input Power is calculated as,

Pi = (V x I x PF x √3)/ 1000

Where:

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Pi = Three-phase power in kW

V = RMS voltage, mean line-to-line of 3 phases

I = RMS current, mean of 3 phases

PF = Power factor as a decimal

Rated power is calculated as,

Pir = (hp x 0.7457)/ηfl

Where:

Pir = Input power at full-rated load in kW

hp = Nameplate rated horsepower

ηfl = Efficiency at full-rated load

Electric motor datasheet usually provides the efficiency and power factor at full load and at various part
loads (for example 50%,75%).

Performance Overview
Equipment Key Performance Indicators (KPIs) view in UAS provides a list of KPIs and their details,
including the current value. This list can be used to review and update asset attribute information, as well
as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if deviates
from the high or low limits.

6.3 Failure Modes

In UAS, a fault model is built to identify possible anomalies that affects the performance or health of a
DC Motor. The fault management can inform operators of any violations of the nominal Motor operating
range and deviations from the expected characteristic and make this data available for further
processing through the historian.

The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions

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 o Low Efficiency: Occurs mainly due to improper load conditions. At low load, the frictional losses
cause low efficiency of the motor. At high load, as the load torque increases the speed of the motor
decreases which will impact the motor efficiency. Hence, it is required to optimize the load on motor
to achieve maximum efficiency.
o Overheating: Occurs due to excessive load on motor which will cause damage to the motor. It is
important to monitor the housing and winding temperatures to maintain the health of the motor.

Below table illustrates the list of faults and symptoms configured for a DC Motor.
Fault
Fault Name Associated Symptoms
Category

Low Efficiency

Performance Performance Degradation Warning High Load

Low Load

Health Health Degradation Warning High Housing Temperature

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

6.4 Configuration
The calculation model to perform as expected, it requires some inputs are to be feed into the model. The
DC Motor model input data consists of measured data and static data. Measured input data is supplied
to the model from DCS or Historian by tag mapping. This section describes the list of input and output
attributes and its properties.

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Model Input data
S Attribute Monitoring
Attribute Description Units Source
No Category Category

Motor Active Motor Active

1 Power Power(Input) kW Dynamic Process Field Input
2 Motor Current Motor Current (Input) Amperes Dynamic Process Field Input
Motor Power Motor Power Factor
3 Factor (Input) Dynamic Process Field Input
Motor
Housing Motor Housing
4 Temperature Temperature (Input) deg C Dynamic Process Field Input
5 Motor Voltage Motor Voltage (Input) V Dynamic Process Field Input
Constant A (Expected
6 Constant A efficiency) Static Design Constant
Constant B (Expected Constant
7 Constant B Efficiency) Static Design
Constant C (Expected Constant
8 Constant C Efficiency) Static Design
9 Rated Power Rated Power (Input) Static Design Constant

Model Output data

S Attribute Monitoring
Attribute Description Units Source
No Category Category

Motor Actual Motor Actual

1 Efficiency Efficiency (Output) % Dynamic Performance Calculated

Motor
Calculated Motor Calculated
2 Power Power (Output) kW Dynamic Performance Calculated

Motor Expected Motor Expected

3 Efficiency Efficiency (Output) % Dynamic Performance Calculated

4 Motor Load Motor Load (Output) % Dynamic Performance Calculated

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Configuring a DC Motor in Uniformance Asset Sentinel
To configure a DC Motor assetOpen Uniformance Asset Sentinel, and on the Contents tree
choose Configuration > Assets.

Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter
AS_Motor_DC.

Refer to the following procedures:

o To configure asset connection attributes.
o To map a dynamic attribute to the datasource tags.
o To set the attribute properties for the Attribute Viewer and Performance Overview.
o To manually update asset attribute information.

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 Liquid Phase Valve Monitoring

A valve is used to regulates, directs or controls the flow of a fluid by opening, closing, or partially
obstructing various passageways. A fluid flow direction is from higher pressure to lower pressure. Critical
valves in process requires valve condition monitoring to ensure safety of personnel as well as the
protection of the environment and process plant capital assets. Failure of a critical valve to operate on
demand will have major impact on any process. Hence, it requires regular inspections tests along with
special monitoring system.

Monitoring Valve operating conditions helps to maintain reliable operations. There are two areas that
helps to monitor a valve performance to increase the availability.
o Process and condition monitoring
o Performance and Health monitoring

This document explains valve monitoring philosophy for process, performance, parameters and their
importance.
Item Type
Category Equipment
Equipment Class Valve
Equipment Type Liquid Phase Valve

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Following are the types of valve which are supported in this UAS template:
o Gate Valve
o Globe Valve
o Butterfly Valve
o Ball valve

7.1 Process Performance Monitoring

The following measured parameters are monitored as they have impact on performance and health of
valve, if not maintained in operating range.

Flow: A valve can be used to stop and start as well as throttle or regulate the flow or movement of media
through a system. The given and desired properties of the flow can be used when selecting a valve. Valve
opens for higher flow rate and close when flow need to reduce.

Pressure drop: The pressure drop is the pressure change between the inlet and outlet of the system. The
pressure drop must exist for flow to occur. The actual pressure drop is the difference between the
upstream (inlet) and downstream (outlet) pressures.

Valve Opening: Open/Close valves are expected to pass 100% of the flow without a significant drop in
pressure. They do not throttle the flow so the openings are generally the same size.

Flow Coefficient: The coefficient is used to determine the size that will best allow the valve to pass the
desired flow rate, while providing stable control of the process fluid. The valve flow coefficient is the
number of U.S. gallons per minute of 60°F water that will flow through a valve at a specified opening with
a pressure drop of 1 psi across the valve. It can be used to compare flow capacities of valves of different
sizes, types, and manufacturers. The flow coefficient is different for gases, liquids, and steam and is also
dependent on the pressure drop across the valve. The Cv can apply to either the opening or closing
action depending on the function. The flow coefficient varies based on the media type in the system.

Flow Characteristics: The flow characteristic describes the relationship between the flow coefficient and
the valve stroke. It is inherent to the design of the selected valve. For example, as the valve is opened, the
flow characteristic allows a certain amount of flow through the valve at a particular percentage of the
stroke. This is especially important for throttle control because it controls the flow in a predictable
manner. The flow rate is affected by the flow characteristic as well as the pressure drop. Inherent flow
characteristic is when the valve is operating with a constant pressure drop without considering the
effects of piping. Installed flow characteristics consider both the valve and piping effects. This is also
considered an ideal curve and takes the entire system into account.

Valve Suction Pressure: For low suction pressure valve need to open more to maintain same flow rate
and vice versa.

Valve discharge Pressure: Higher discharge pressure across valve restrict flow.

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Process Performance Overview: Process Performance monitoring view in UAS provides a list of the asset
attributes and their details, including the current value. This list can be used to review and update asset
attribute information, as well as to open an Asset Trend to view more details. It also highlights (in red color)
the attributes if deviates from the high or low limits.

7.2 Performance Monitoring

The effective utilization of the equipment can be monitored with the help of performance indicators.

Key Performance Indicators

The following indicators help us to know overall performance of the valve.

Actual Cv
It is actual amount of fluid flow through a valve at a specified opening with an actual pressure drop
across the valve. Calculated flow capacity based upon current operating conditions.

Actual Cv = Q x (S/DP)1/2

DP = P1 – P2

Where,

Q= Fluid flow in U.S. GPM

S= Specific gravity of fluid relative to water @60 deg F.

P1= Inlet pressure in psia (abs.)

P2= Outlet pressure in psia (abs.)

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Expected Cv
It is maximum (Design)amount of fluid flow through a valve with pressure drop.

Expected Cv=(CT_A*ID_CH+CT_B)/100*CT_Dcv

Where,

CT_A=Valve Characteristic Parameter A

CT_B=Valve Characteristic Parameter B

ID_CH=Valve Closing

CT_Dcv=Valve Design CV

Cv deviations
Difference between Actual Cv and Expected Cv.

Cv deviations = ((Actual Cv – Expected Cv)/ (Expected Cv)) *100

Cv available
Ratio of Actual Cv and Expected Cv.

Cv available = (Actual Cv / Expected Cv) *100

Performance Overview
Equipment Key Performance Indicators (KPIs) view in UAS provides a list of KPIs and their details,
including the current value. This list can be used to review and update asset attribute information, as
well as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if
deviates from the high or low limits.

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7.3 Failure Modes
In UAS, a fault model is built to identify possible anomalies that affects the performance or health of a
liquid phase valve. The fault management can inform operators of any violations of the nominal valve
operating range and deviations from the expected characteristic and make this data available for further
processing through the historian.
The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions

Choked Flow: It is the maximum or limiting flow rate with increasing pressure differential with fixed
upstream conditions. When the pressure drop across the valve is high enough, the flow passage at the
vena contracta becomes fully occupied by vapor and choked flow occurs. This also causes cavitation
inside the pipe which will damage the valve. Hence, it is required to monitor the deltaP across the valve
against limit.

CV Deviation: Cv is an important measurement for the maximum flow condition across valve defined at
the time of valve sizing. More deviation in Cv represents there is not a lot of increasing of the flow area
before the max Cv out of the valve is reached.

Below table illustrates the list of faults and symptoms configured for a DC Motor.

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

Below table illustrates the list of faults and symptoms configured for a liquid phase valve.

Fault Category Fault Name Associated Symptoms

Performance Warning Cv Deviation High

Performance Leakage Warning Total Flow Rate High

Chocking Warning Actual DP High

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

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7.4 Configuration
The calculation model to perform as expected, it requires some inputs are to be feed into the model. The
DC Motor model input data consists of measured data and static data. Measured input data is supplied
to the model from DCS or Historian by tag mapping. This section describes the list of input and output
attributes and its properties.

Model Input data

S Attribute Monitoring
Attribute Description Units Source
No Category Category

Rotor Diameter Constant From

1 Rotor Diameter (Input) Static Design Manufacturer Data Sheet

Suction Pipe Suction Pipe Constant From

2 Diameter Diameter (Input) Static Design Manufacturer Data Sheet

Discharge Pipe Discharge Pipe Constant From

3 Diameter Diameter (Input) Static Design Manufacturer Data Sheet
Valve Design Valve Design CV
4 CV (Input) Static Design Constant
Valve Pressure Valve Pressure
Recovery Recovery Factor
5 Factor (Input) Static Design Constant
Gravitational
Gravitational Acceleration
6 Acceleration (Input) Static Design Constant
Valve
Valve Characteristic
Characteristic Parameter A
7 Parameter A (Input) Static Design Constant
Valve Valve
8 Characteristic Characteristic Static Design Constant

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 S Attribute Monitoring
Attribute Description Units Source
No Category Category
Parameter B Parameter B
(Input)
Constant N1
9 Constant N1 (don’t change) Static Design Constant
Constant N2
10 Constant N2 (don’t change) Static Design Constant
11 Constant N6 Constant N6 Dynamic Design Constant
12 Travel Travel (Input) % Dynamic Process Field Input
Upstream Upstream
13 Pressure Pressure (Input) barg Dynamic Process Field Input
Downstream Downstream
14 Pressure Pressure (Input) barg Dynamic Process Field Input
Fluid Density Thermo
15 Fluid Density (Input) Dynamic Properties Lab Measurement
Liquid Mass Liquid Mass Flow
16 Flow (Input) tons/hr Dynamic Process Field Input
17 Running Status Running Status Dynamic Process Field Input

Model Output data

S Attribute Monitoring
Attribute Description Units Source
No Category Category

Constant From
Rotor Rotor Diameter Manufacturer Data
1 Diameter (Input) Static Design Sheet
Suction Pipe Constant From
Suction Pipe Diameter Manufacturer Data
2 Diameter (Input) Static Design Sheet
Discharge Pipe Constant From
Discharge Diameter Manufacturer Data
3 Pipe Diameter (Input) Static Design Sheet
Valve Design Valve Design CV
4 CV (Input) Static Design Constant

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Configuring a Liquid-Phase Valve in Uniformance Asset
Sentinel
To configure a Liquid-Phase Valve with performance/Fault model

Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter
AS_Valve_Liquid.

Refer to the following procedures:

o To configure asset connection attributes.
o To map a dynamic attribute to the datasource tags.
o To set the attribute properties for the Attribute Viewer and Performance Overview.
o To manually update asset attribute information.

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 Two Phase Valve Monitoring

A valve is used to regulates, directs or controls the flow of a fluid by opening, closing, or partially
obstructing various passageways. A fluid flow direction is from higher pressure to lower pressure. Two
phase valves used to control gas-liquid, liquid-liquid, solid-liquid type of flow. Critical valves in process
requires valve condition monitoring to ensure safety of personnel as well as the protection of the
environment and process plant capital assets. Failure of a critical valve to operate on demand will have
major impact on any process. Hence, it requires regular inspections tests along with special monitoring
system.

Monitoring Valve operating conditions helps to maintain reliable operations. There are two areas that
helps to monitor a valve performance to increase the availability.
o Process and condition monitoring
o Performance and Health monitoring

This document explains valve monitoring philosophy for process, performance, parameters and their
importance.
Item Type
Category Equipment
Equipment Class Valve
Equipment Type Two Phase Valve

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Following are the types of valve which are supported in this UAS template:
o Gate Valve
o Globe Valve
o Ball valve

8.1 Process Performance Monitoring

The following measured parameters are monitored as they have impact on performance and health of
valve, if not maintained in operating range.

Flow: A valve can be used to stop and start as well as throttle or regulate the flow or movement of media
through a system. The given and desired properties of the flow can be used when selecting a valve. Valve
opens for higher flow rate and close when flow need to reduce.

Pressure drop: The pressure drop is the pressure change between the inlet and outlet of the system. The
pressure drop must exist for flow to occur. The formula is as follows:ΔP = G (q/FpCv)2 Disc position will
generally determine the pressure drop. For example, if the valve is closed the pressure drop will be
minimal or zero and if the valve is open the pressure drop is 100%. If the pressure drop is too high, a
larger valve or a valve with a higher Cv can be used to lower the pressure. The actual pressure drop is
the difference between the upstream (inlet) and downstream (outlet) pressures.

Valve Opening: Open/Close valves are expected to pass 100% of the flow without a significant drop in
pressure. They do not throttle the flow so the openings are generally the same size.

Flow Coefficient: The coefficient is used to determine the size that will best allow the valve to pass the
desired flow rate, while providing stable control of the process fluid. The valve flow coefficient is the
number of U.S. gallons per minute of 60°F water that will flow through a valve at a specified opening with
a pressure drop of 1 psi across the valve. It can be used to compare flow capacities of valves of different
sizes, types, and manufacturers. The flow coefficient is different for gases, liquids, and steam and is also
dependent on the pressure drop across the valve. The Cv can apply to either the opening or closing
action depending on the function. The flow coefficient varies based on the media type in the system.

Flow Characteristics: The flow characteristic describes the relationship between the flow coefficient and
the valve stroke. It is inherent to the design of the selected valve. For example, as the valve is opened, the
flow characteristic allows a certain amount of flow through the valve at a particular percentage of the
stroke. This is especially important for throttle control because it controls the flow in a predictable
manner. The flow rate is affected by the flow characteristic as well as the pressure drop. Inherent flow
characteristic is when the valve is operating with a constant pressure drop without considering the
effects of piping. Installed flow characteristics consider both the valve and piping effects. This is also
considered an ideal curve and takes the entire system into account.

Valve Suction Pressure: For low suction pressure valve need to open more to maintain same flow rate
and vice versa.

Valve discharge Pressure: Higher discharge pressure across valve restrict flow.

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Process Performance Overview: Process Performance monitoring view in UAS provides a list of the
asset attributes and their details, including the current value. This list can be used to review and update
asset attribute information, as well as to open an Asset Trend to view more details. It also highlights (in
red color) the attributes if deviates from the high or low limits.

8.2 Performance Monitoring

The effective utilization of the equipment can be monitored with the help of performance indicators.

Key Performance Indicators

The following indicators help us to know overall performance of the valve.

Actual Cv
It is actual amount of fluid flow through a valve at a specified opening with an actual pressure drop across
the valve. Calculated flow capacity based upon current operating conditions.

Actual Cv =Cv for liquid phase + Cv for Gas phase

Cv(liquid) = ((CV_W_W+CV_W_O)/(CT_N1*CV_rho_L*Fp))*SQRT(CV_rho_L/(1000*(CV_P1-CV_P2)))

Cv(Gas)= CV_W_G/(CT_N8*Fp*CV_P1*CV_Y) *SQRT(CV_T1*CT_Z/(CV_DP_R*CT_M))

Where,

CV_W_W=Water mass flow

CV_W_O = Oil mass flow

CT_N1 = Constant 0.86

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CV_rho_L = Liquide fraction density

Fp =Piping geometric factor

CV_P1 =Suction pressure

CV_P2 =Discharge Pressure

CV_W_G=Gas mass flow rate

CT_N8 =Constant 94.80

Fp = Piping geometric factor

CV_P1= Suction pressure

CV_Y =Gas expansion factor 0.87

CV_T1=Suction temp

CT_Z=Gas compressibility factor 0.98

CV_DP_R= Pressure Drop Ratio

CT_M =Gas molecular wt.

Expected Cv
It is maximum (Design)amount of fluid flow through a valve with a pressure drop.

Expected Cv=(CT_A*ID_CH+CT_B)/100*CT_Dcv

Where,

CT_A=Valve Characteristic Parameter A

CT_B=Valve Characteristic Parameter B

ID_CH=Valve Closing

CT_Dcv=Valve Design CV

Cv deviations
Difference between Actual Cv and Expected Cv.

Cv deviations = ((Actual Cv – Expected Cv)/ (Expected Cv)) *100

Cv available
Ratio of Actual Cv and Expected Cv.

Cv available = (Actual Cv / Expected Cv) *100

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Performance Overview
Equipment Key Performance Indicators (KPIs) view in UAS provides a list of KPIs and their details,
including the current value. This list can be used to review and update asset attribute information, as
well as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if
deviates from the high or low limits.

8.3 Failure Modes

In UAS, a fault model is built to identify possible anomalies that affects the performance or health of a
DC Motor. The fault management can inform operators of any violations of the nominal Motor operating
range and deviations from the expected characteristic and make this data available for further
processing through the historian.
The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions

Choked Flow: It is the maximum or limiting flow rate with increasing pressure differential with fixed
upstream conditions. When the pressure drop across the valve is high enough, the flow passage at the
vena contracta becomes fully occupied by vapor and choked flow occurs. This also causes cavitation
inside the pipe which will damage the valve. Hence, it is required to monitor the deltaP across the valve
against limit.

CV Deviation: Cv is an important measurement for the maximum flow condition across valve defined at
the time of valve sizing. More deviation in Cv represents there is not a lot of increasing of the flow area
before the max Cv out of the valve is reached.

Below table illustrates the list of faults and symptoms configured for a two phase valve.

Fault Category Fault Name Associated Symptoms

Performance Performance Warning Cv Deviation High

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 Fault Category Fault Name Associated Symptoms

Leakage Warning Total Flow Rate High

Chocking Warning Actual DP High
Liquid Phase Flow is Choked
Health Health Warning
Gas Phase Flow is Choked

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

8.4 Configuration
The calculation model to perform as expected, it requires some inputs are to be feed into the model. The
DC Motor model input data consists of measured data and static data. Measured input data is supplied
to the model from DCS or Historian by tag mapping. This section describes the list of input and output
attributes and its properties.

Model Input data

S Attribute Monitoring
Attribute Description Units Source
No Category Category

Constant
From
Manufact
Rotor urer Data
1 Diameter Rotor Diameter (Input) Static Design Sheet
Constant
From
Manufact
Suction Pipe Suction Pipe Diameter urer Data
2 Diameter (Input) Static Design Sheet
Constant
From
Discharge Discharge Pipe Manufact
3 Pipe Diameter Diameter (Input) Static Design urer Data

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 S Attribute Monitoring
Attribute Description Units Source
No Category Category
Sheet

Valve
Characteristic Valve Characteristic
4 Parameter A Parameter A Static Design Constant
Valve
Characteristic Valve Characteristic
5 Parameter B Parameter B Static Design Constant
Valve Design Valve Design CV
6 CV (Input) Static Design Constant
Valve Pressure Valve Pressure
Recovery Recovery Factor
7 Factor (Input) Static Design Constant
Gravitational Gravitational
8 Acceleration Acceleration (Input) Static Design Constant
Gas Specific Gas Specific Heat Thermo
9 Heat Ratio Ratio (Input) Static Properties Constant
Gas Molecular Gas Molecular Weight Thermo
10 Weight (Input) Static Properties Constant
Constant N1 (don’t
11 Constant N1 change-fix value) Static Design Constant
Constant N2 (don’t
12 Constant N2 change-fix value) Static Design Constant
Constant N5 (don’t
13 Constant N5 change-fix value) Static Design Constant
Constant N8 (don’t
14 Constant N8 change-fix value) Static Design Constant
Lab
Critical Point Critical Point Pressure Thermo Measurem
15 Pressure - Gas - Gas (Input) Static Properties ent
Critical Point Lab
Pressure - Critical Point Pressure Thermo Measurem
16 Liquid - Liquid (Input) Static Properties ent
Vapor Lab
Pressure at T1 Vapor Pressure at T1 - Thermo Measurem
17 - Liquid Liquid (Input) Static Properties ent
Valve PD Ratio Valve PD Ratio Factor
18 Factor (Input) Static Design Constant
Gas Lab
Compressibilit Gas Compressibility Thermo Measurem
19 y Factor Factor (Input) Static Properties ent
20 Travel Travel (Input) % Dynamic Process Field Input

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 S Attribute Monitoring
Attribute Description Units Source
No Category Category

Upstream Upstream Pressure

21 Pressure (Input) barg Dynamic Process Field Input
Downstream Downstream Pressure
22 Pressure (Input) barg Dynamic Process Field Input
Lab
Thermo Measurem
23 Gas Density Gas Density (Input) Dynamic Properties ent
Lab
Thermo Measurem
24 Oil Density Oil Density (Input) Dynamic Properties ent
Lab
Thermo Measurem
25 Water Density Water Density (Input) Dynamic Properties ent
Suction Suction Temperature
26 Temperature (Input) deg C Dynamic Process Field Input
27 Gas Mass Flow Gas Mass Flow (Input) kg/hr Dynamic Process Field Input
28 Oil Mass Flow Oil Mass Flow (Input) kg/hr Dynamic Process Field Input
Water Mass Water Mass Flow
29 Flow (Input) kg/hr Dynamic Process Field Input

Model Output data

Attribute Monitoring
S No Attribute Description Units Source
Category Category

1 Actual Cv Actual Cv (Output) Double Performance Calculated

2 Deviation Cv Deviation Cv (Output) Double Performance Calculated
Differential Differential Pressure
3 Pressure (Output) bara Double Performance Calculated
4 Expected Cv Expected Cv (Output) Double Performance Calculated
Gas Fraction
5 [%] Gas Fraction [%] (Output) % Double Performance Calculated
Liquid Fraction Liquid Fraction [%]
6 [%] (Output) % Double Performance Calculated
7 Oil Fraction [%] Oil Fraction [%] (Output) % Double Performance Calculated

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Configuring a Two-Phase Valve in Uniformance Asset
Sentinel
To configure a Two-Phase Valve with performance/Fault model

Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter
AS_Valve_Liquid.

Refer to the following procedures:

o To configure asset connection attributes.
o To map a dynamic attribute to the datasource tags.
o To set the attribute properties for the Attribute Viewer and Performance Overview.
o To manually update asset attribute information.

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 Furnace Monitoring

Furnace is an exchanger that transfers heat from the combustion of fuel to fluids contained in tubular
coils within an internally insulated enclosure. It is used to provide heat for a process or can serve
as reactor which provides heats of reaction. Furnace designs vary as to its function, heating duty, type
of fuel and method of introducing combustion air. Heat is generated by an Furnace by mixing fuel with
air or oxygen, or from electrical energy. The residual heat will exit the furnace as flue gas.

An industrial Furnace comprises below segments,

Radiant section: The radiant section is where the tubes receive almost all its heat by radiation from
the flame. In a vertical, cylindrical Furnace, the tubes are vertical. Tubes can be vertical or horizontal,
placed along the refractory wall, in the middle, etc., or arranged in cells. Studs are used to hold
the insulation together and on the wall of the furnace. The tubes are a distance away from the
insulation so radiation can be reflected to the back of the tubes to maintain a uniform tube wall
temperature. Tube guides at the top, middle and bottom hold the tubes in place.

Convection section: The convection section is located above the radiant section where it is cooler to
recover additional heat. Heat transfer takes place by convection here, and the tubes are finned to
increase heat transfer. The first two tube rows in the bottom of the convection section and at the top of
the radiant section is an area of bare tubes (without fins) and are known as the shield section ("shock
tubes"), so named because they are still exposed to plenty of radiation from the firebox and they also act
to shield the convection section tubes, which are normally of less resistant material from the high
temperatures in the firebox. The area of the radiant section just before flue gas enters the shield section
and into the convection section called the bridgezone. A crossover is the tube that connects from the
convection section outlet to the radiant section inlet. The crossover piping is normally located outside so
that the temperature can be monitored and the efficiency of the convection section can be calculated.
The sightglass at the top allows personnel to see the flame shape and pattern from above and visually
inspect if flame impingement is occurring. Flame impingement happens when the flame touches the
tubes and causes small isolated spots of very high temperature.

Radiant coil: This is a series of tubes horizontal/ vertical hairpin type connected at ends (with 180°
bends) or helical in construction. The radiant coil absorbs heat through radiation. They can be single
pass or multi pass depending upon the process-side pressure drop allowed. The radiant coils and bends
are housed in the radiant box. Radiant coil materials vary from carbon steel for low temperature services
to high alloy steels for high temperature services. These are supported from the radiant side walls or
hanging from the radiant roof. Material of these supports is generally high alloy steel. While designing
the radiant coil, care is taken so that provision for expansion (in hot conditions) is kept.

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Burner: The burner in the vertical, cylindrical Furnace is located in the floor and fires upward. Some
Furnace has side fired burners, such as in train locomotives. The burner tile is made of high
temperature refractory and is where the flame is contained. Air registers located below the burner and at
the outlet of the air blower are devices with movable flaps or vanes that control the shape and pattern of
the flame, whether it spreads out or even swirls around. Flames should not spread out too much, as this
will cause flame impingement. Air registers can be classified as primary, secondary and if applicable,
tertiary, depending on when their air is introduced. The primary air register supplies primary air, which is
the first to be introduced in the burner. Secondary air is added to supplement primary air. Burners may
include a pre-mixer to mix the air and fuel for better combustion before introducing into the burner.
Some burners even use steam as premix to preheat the air and create better mixing of the fuel and
heated air. The floor of the furnace is mostly made of a different material from that of the wall, typically
hard castable refractory to allow technicians to walk on its floor during maintenance. A furnace can be lit
by a small pilot flame or in some older models, by hand. Most pilot flames nowadays are lit by an
ignition transformer (much like a car's spark plugs). The pilot flame in turn lights up the main flame. The
pilot flame uses natural gas while the main flame can use both diesel and natural gas. When using
liquid fuels, an atomizer is used, otherwise, the liquid fuel will simply pour onto the furnace floor and
become a hazard. Using a pilot flame for lighting the furnace increases safety and ease compared to
using a manual ignition method (like a match).

Sootblower: Sootblowers are found in the convection section. As this section is above the radiant section
and air movement is slower because of the fins, soot tends to accumulate here. Sootblowing is
normally done when the efficiency of the convection section is decreased. This can be calculated by
looking at the temperature change from the crossover piping and at the convection section exit.
Sootblowers utilize flowing media such as water, air or steam to remove deposits from the tubes. This is
typically done during maintenance with the air blower turned on. There are several different types of
sootblowers used. Wall blowers of the rotary type are mounted on furnace walls protruding between the
convection tubes. The lances are connected to a steam source with holes drilled into it at intervals

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along its length. When it is turned on, it rotates and blows the soot off the tubes and out through the
stack.

Stack: The flue gas stack is a cylindrical structure at the top of all the heat transfer chambers.
The breeching directly below it collects the flue gas and brings it up high into the atmosphere where it
will not endanger personnel. The stack damper contained within works like a butterfly valve and
regulates draft(pressure difference between air intake and air exit) in the Furnace, which is what pulls
the flue gas through the convection section. The stack damper also regulates the heat lost through the
stack. As the damper closes, the amount of heat escaping the Furnace through the stack decreases, but
the pressure or draft in the furnace increases which poses risks to those working around it if there are
air leakages in the furnace, the flames can then escape out of the firebox or even explode if the pressure
is too great.

Individually, each of these important indicators collectively, they provide a complete picture as to the
actual condition of the Furnace. This document explains Furnace monitoring philosophy for process,
performance, energy and health parameters and their importance.

Monitoring Basic machine health data in addition to Furnace operating conditions helps to maintain
reliable Furnace operations. There are three areas that helps to monitor pump performance to increase
the availability and decrease the energy costs.
o Process and condition monitoring
o Energy monitoring
o Performance and Health monitoring

Item Type
Category Equipment
Equipment Class Heaters
Equipment Type Furnace

9.1 Process Performance Monitoring

The following measured parameters are monitored as it has following impact on performance and health
of the furnace if not operated in operating range.

Stack O2 % – This indicates Air or O2 percent in the exit gases of the furnace. More O2 indicates that
the furnace is operating at more AF (air to fuel) ratio. More O2 content than desired indicates losses to
preheat excess air supply to combustion temperature. Less O2 indicates that the furnace is operating at
lower AF (air to fuel) ratio. This can cause incomplete combustion of fuel and reduce thermal efficiency
of the furnace.

NOX Emissions: This indicates current NOx ppm levels in the exit gases of the furnace. More of NO2
emissions is hazardous for the environment.

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CO Emission: This indicates current CO ppm levels in the exit gases of the furnace. More the level
indicates incomplete combustion of fuel and lower efficiency of the furnace. More CO levels adds risk for
plant and environment safety as well.

Flue Gas Temp/ Stack Temp: This indicates exit gas/stack gas temperature of the furnace. More the
temperature indicates in-efficient use of combustion energy.

Furnace Draft It indicates furnace draft pressure.

Process Performance Overview: Process Performance monitoring view in UAS provides a list of the
asset attributes and their details, including the current value. This list can be used to review and update
asset attribute information, as well as to open an Asset Trend to view more details. It also highlights (in
red color) the attributes if deviates from the high or low limits.

9.2 Energy Monitoring

Energy Monitoring explains the KPIs to be monitored to optimize the energy consumption by furnace.

Heat Losses:This indicates the total heat losses in furnace

Heat Losses = Stack Heat Loss + Radiation Loss

9.3 Performance Monitoring

The effective utilization of the equipment can be monitored with the help of performance indicators.

Key Performance Indicators

The following indicators help to know the overall performance of the furnace

Thermal Efficiency: Thermal efficiency is defined as the percentage of heat available to heat process
fluid with respect to heat supplied. It accounts losses due to air and fuel preheating, air relative humidity,
stack and radiation losses. Process side heat balance is not considered in furnace efficiency
calculations.

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 1. Total moisture in combustion air is calculated as:

𝑉𝑉𝑉𝑉𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 𝑝𝑝𝑝𝑝. 𝑜𝑜𝑜𝑜 𝑤𝑤𝑤𝑤t𝑒𝑒𝑒𝑒 𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅 ℎ𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢 18

𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀 𝑖𝑖𝑖𝑖 𝑎𝑎𝑎𝑎𝑎𝑎 = + +
101.325 100 28.85

2. Total wet air per Kg of fuel required is calculated as:

𝐾𝐾𝐾𝐾 𝑜𝑜𝑜𝑜 𝑎𝑎𝑎𝑎𝑎𝑎 𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟

𝐾𝐾𝐾𝐾 𝑜𝑜𝑜𝑜 𝑤𝑤𝑤𝑤𝑤𝑤 𝑎𝑎𝑎𝑎𝑎𝑎 𝑝𝑝𝑝𝑝𝑝𝑝 𝐾𝐾𝐾𝐾 𝑜𝑜𝑜𝑜 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 =
1 − 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑖𝑖𝑖𝑖 𝑎𝑎𝑎𝑎𝑎𝑎

3. Total moisture per Kg of fuel is calculated as:

𝐾𝐾𝐾𝐾 𝑜𝑜𝑜𝑜 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑝𝑝𝑝𝑝𝑝𝑝 𝐾𝐾𝐾𝐾 𝑜𝑜𝑜𝑜 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 = 𝐾𝐾𝐾𝐾 𝑜𝑜𝑜𝑜 𝑤𝑤𝑤𝑤𝑤𝑤 𝑎𝑎𝑎𝑎𝑎𝑎 𝑝𝑝𝑝𝑝𝑝𝑝 𝐾𝐾𝐾𝐾 𝑜𝑜𝑜𝑜 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 − 𝐾𝐾𝐾𝐾 𝑜𝑜𝑜𝑜 𝑎𝑎𝑎𝑎𝑎𝑎 𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟

4. Total excess air per Kg of fuel is calculated as:

𝑁𝑁2 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 𝐶𝐶𝐶𝐶2 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 𝐻𝐻2𝑂𝑂 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓

(28.85 ∗ % 𝑂𝑂2) � + + �
28 44 18
𝐾𝐾𝐾𝐾 𝑜𝑜𝑜𝑜 𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 𝑎𝑎𝑎𝑎𝑎𝑎 𝑝𝑝𝑝𝑝𝑝𝑝 𝐾𝐾𝐾𝐾 𝑜𝑜𝑜𝑜 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 =
𝐾𝐾𝐾𝐾 𝑜𝑜𝑜𝑜 𝐻𝐻2𝑂𝑂
20.95 − % 𝑂𝑂2 ��1.6028 ∗ � + 1�
𝐾𝐾𝐾𝐾 𝑜𝑜𝑜𝑜 𝑎𝑎𝑎𝑎𝑎𝑎 𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟

5. Percentage excess air is calculated as:

𝐾𝐾𝐾𝐾 𝑜𝑜𝑜𝑜 𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 𝑎𝑎𝑎𝑎𝑎𝑎 𝑝𝑝𝑝𝑝𝑝𝑝 𝑘𝑘𝑘𝑘 𝑜𝑜𝑜𝑜 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓

𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 𝑎𝑎𝑎𝑎𝑎𝑎 = ∗ 100
𝐾𝐾𝐾𝐾 𝑜𝑜𝑜𝑜 𝑎𝑎𝑎𝑎𝑎𝑎 𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟

6. Net thermal efficiency is calculated as:

𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 ℎ𝑒𝑒𝑒𝑒𝑒𝑒 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎

𝑁𝑁𝑁𝑁𝑁𝑁 𝑡𝑡ℎ𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 = ∗ 100
𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 ℎ𝑒𝑒a𝑡𝑡 𝑖𝑖𝑖𝑖𝑝𝑝𝑝𝑝𝑝𝑝

(ℎ𝐿𝐿 + ∆ℎ𝑎𝑎 + ∆ℎ𝑓𝑓 + ∆ℎ𝑚𝑚) − (ℎ𝑟𝑟 + ℎ𝑠𝑠)

𝐸𝐸 = ∗ 100
(ℎ𝐿𝐿 + ∆ℎ𝑎𝑎 + ∆ℎ𝑓𝑓 + ∆ℎ𝑚𝑚)

Where,

Stack heat loss is calculated based on Flue gas enthalpy difference at stack temperature and at
datum temperature (15 Deg. C). The Flue gas quantity is calculated based on theoretical air
requirement for complete combustion of fuel and excess O2 content in the stack.
Radiation losses are expressed as fixed percentage of Fuel LHV as per norms defined in API
560.
Radiation Loss = Radiation Loss %× LHV /100
Radiation loss% is defined in UAS template as below,

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 1.5% - No air preheater means air enters the Furnace at ambient temperature
2.5% - Air is preheated to improve the furnace efficiency. In this air temperature value should be
taken based on measurement after air preheater.

Mean specific heat of process fluid Kcal /Kg oC Cp

Lower heating value of the fuel burned Kcal /Kg hL

Higher heating value of the fuel burned Kcal /Kg hH

Specific heat capacity of the air Kcal /Kg oC Cp a

Specific heat capacity of the fuel Kcal /Kg oC Cp f

Specific heat capacity of the atomizing medium Kcal/Kg oC Cp m

Ambient air sensible heat correction due to SPH Kcal/Kg Δha

Fuel sensible heat correction Kcal /Kg Δhf

Atomizing medium sensible heat correction Kcal /Kg Δhm

Radiation heat loss Kcal /Kg hr

Stack heat loss Kcal /Kg hs

7. Fuel efficiency calculated as:

𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 ℎ𝑒𝑒𝑒𝑒𝑒𝑒 𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎

𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹 𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 = ∗ 100
𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 𝑑𝑑𝑑𝑑𝑑𝑑 𝑡𝑡𝑡𝑡 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑜𝑜𝑜𝑜 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜

(ℎ𝐿𝐿 + ∆ℎ𝑎𝑎 + ∆ℎ𝑓𝑓 + ∆ℎ𝑚𝑚) − (ℎ𝑟𝑟 + ℎ𝑠𝑠)

𝐸𝐸𝐸𝐸 = ∗ 100
ℎ𝐿𝐿

• Projected Energy Loss:

This indicates the projected energy loss in the year based on current energy loss.

Energy Loss = Heat Losses × Mf /1000

Energy Loss PerHr = (Energy Loss × (Fuel Cost/1000)) / (3600/1000)

Projected Energy Loss = Energy Loss PerHr × 8400

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Performance Overview
Equipment Key Performance Indicators (KPIs) view in UAS provides a list of KPIs and their details,
including the current value. This list can be used to review and update asset attribute information, as well
as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if deviates
from the high or low limits.

9.4 Failure Modes

In UAS, a fault model is built to identify possible anomalies that affects the performance or health of a
furnace. The fault management can inform operators of any violations of the nominal furnace operating
range and deviations from the expected characteristic and make this data available for further
processing through the historian. The fault symptoms or models are used to:
o Warn against potential damage to furnace under unfavorable operating conditions.
o Provide early warning of damages to the furnace.

The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions
o Low Furnace efficiency: It is determined by means of the deviation of the current Furnace
efficiency from the design efficiency.
o Incomplete combustion: It indicate fuel is not completely utilized to generate heat in form of
energy. It can be determining by stack C0, NOX and O2 concentration.
o Backfire: It indicate pressure inside Furnace is higher which resist burning of fuel. This can be
happed due to high draft pressure and low stack damper opening.
o Hotspot on tubes: This determines by high skin temperature and can damage tubes of Furnace.

Below table illustrates the list of faults and symptoms configured for a Furnace.

Fault
Fault Name Associated Symptoms
Category

Fuel Efficiency Low

Performance Performance Low Warning Thermal Efficiency Low
Stack Temperature High
Stack O2 High with High Draft

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 Fault
Fault Name Associated Symptoms
Category

Stack O2 Low with High Draft

Stack O2 High with Low Draft
Stack O2 Low with Low Draft
Stack O2 Low at Target Draft
Stack O2 High at Target Draft
Performance Poor Operations Positive Ach Pressure
Fuel BackPressure High
CO Emissions High
Performance Incomplete Combustion NOx Emission High
Air to Fuel Ratio Low
Air to Fuel Ratio High
Fuel Efficiency Low
Thermal Efficiency Low
Performance Performance Low Warning Stack Oxygen High
Stack Oxygen Low
Stack Oxygen Low
Stack Temperature High
Performance Poor Operations Positive Ach Pressure
Fuel BackPressure High
CO Emissions High
NOx Emission High
Performance Incomplete Combustion
Air to Fuel Ratio Low
Air to Fuel Ratio High
Furnace Pressure Rapid Change
Health Potential SuperHeater Tubeleak Damper Opening Rapid Change
SH Temp Diff Rapid Change
Flue Gas Temp Rapid Change
Health Potential Convection WaterWall Tubeleak Furnace Pressure Rapid Change
Damper Opening Long Term Change

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

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9.5 Configuration
As described in previous sections, Furnace performance monitoring model is used to:
o Calculate the current operating point data such as heat loss,load and efficiency. The calculation is
performed based on the inputs received from DCS/Historian or based on the configured model
parameters.

The calculation model to perform as expected, it requires some inputs are to be feed into the model. The
Furnace model input data consists of measured data and static data. Measured input data is supplied to
the model from DCS or Historian by tag mapping. This section describes the list of input and output
attributes and its properties.

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Model Input data

S Attribute Monitoring
Attribute Description Units Source
No Category Category

Air Specific Heat Thermo Interconnecti

1 Air Specific Heat (Output) kJ/kg-C Dynamic Properties on
Thermo Interconnecti
2 Air Density Air Density (Output) kg/m3 Dynamic Properties on
Thermo Interconnecti
3 Air Enthalpy Air Enthalpy (Output) kJ/kg Dynamic Properties on
4 Air Pressure Air Pressure (Input) barg Dynamic Process Field Input
Relative Humidity
5 Relative Humidity (Input) % Dynamic Process Field Input
Ambient Ambient Temperature
6 Temperature (Input) deg C Dynamic Process Field Input
Datum Datum Temperature
7 Temperature (Input) deg C Dynamic Design Field Input
Thermo Interconnecti
8 Flue Gas Cp Flue Gas Cp (Output) kJ/kg-C Dynamic Properties on
Flue Gas Density Thermo Interconnecti
9 Flue Gas Density (Output) kg/m3 Dynamic Properties on
Flue Gas Enthalpy Thermo Interconnecti
10 Flue Gas Enthalpy (Output) kJ/kg Dynamic Properties on
Flue Gas Oxygen
11 Flue Gas Oxygen (Input) Dynamic Process Field Input
Flue Gas Flue Gas Temperature
12 Temperature (Required Input) deg C Dynamic Process Field Input
Fuel Back Pressure
13 Fuel Back Pressure (Input) barg Dynamic Process Field Input
Fuel_CompoundDa Thermo
14 ta Fuel_CompoundData Dynamic Properties Field Input
Thermo
15 Fuel Density Fuel Density (Input) kg/m3 Dynamic Properties Field Input
16 Fuel LHV Fuel LHV (Input) kJ/kg Dynamic Process Field Input
17 Fuel Mass Flow Fuel Mass Flow (Input) kg/hr Dynamic Process Field Input
inches_H2
18 Furnace Draft Furnace Draft (Input) O Dynamic Process Field Input
Furnace Pressure
19 Furnace Pressure (Input) barg Dynamic Process Field Input
20 Inlet1 Port Static Connection Field Input
Components,MoleFract Thermo
21 CompoundData ion Dynamic Properties Field Input
Inlet1_Energy (Asset Thermo
22 Inlet1_Energy Connection Input) kJ/kg Dynamic Properties Field Input

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 Inlet2_Compound Components,MoleFract Thermo
23 Data ion Dynamic Properties Field Input
Inlet2_Energy (Asset Thermo
24 Inlet2_Energy Connection Input) kJ/kg Dynamic Properties Field Input
Inlet3_Compound Components,MoleFract Thermo
25 Data ion Dynamic Properties Field Input
Inlet3_Energy (Asset Thermo
26 Inlet3_Energy Connection Input) kJ/kg Dynamic Properties Field Input
Percent Radiation Percent Radiation Loss
27 Loss (Input) % Dynamic Design Field Input
Superheater Skin
Temperature
28 SH Skin Temp 1 Measurement 1 deg C Dynamic Process Field Input
Superheater Skin
Temperature
29 SH Skin Temp 10 Measurement 10 deg C Dynamic Process Field Input
Superheater Skin
Temperature
30 SH Skin Temp 11 Measurement 11 deg C Dynamic Process Field Input
Superheater Skin
Temperature
31 SH Skin Temp 12 Measurement 12 deg C Dynamic Process Field Input
Superheater Skin
Temperature
32 SH Skin Temp 2 Measurement 2 deg C Dynamic Process Field Input
Superheater Skin
Temperature
33 SH Skin Temp 3 Measurement 3 deg C Dynamic Process Field Input
Superheater Skin
Temperature
34 SH Skin Temp 4 Measurement 4 deg C Dynamic Process Field Input
Superheater Skin
Temperature
35 SH Skin Temp 5 Measurement 5 deg C Dynamic Process Field Input
Superheater Skin
Temperature
36 SH Skin Temp 6 Measurement 6 deg C Dynamic Process Field Input
Superheater Skin
Temperature
37 SH Skin Temp 7 Measurement 7 deg C Dynamic Process Field Input
Superheater Skin
Temperature
38 SH Skin Temp 8 Measurement 8 deg C Dynamic Process Field Input
Superheater Skin
Temperature
39 SH Skin Temp 9 Measurement 9 deg C Dynamic Process Field Input
40 Surface Area Surface Area (Input) m2 Dynamic Design Field Input

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 Surface Surface Temperature
41 Temperature (Input) deg C Dynamic Design Field Input
Absolute Humidity Interconnecti
42 Absolute Humidity (Output) % Dynamic Combustion on
Interconnecti
43 Air Mass Flow Air Mass Flow kg/hr Dynamic Combustion on
cubic_metr Interconnecti
44 Air Min Flow Air Min Flow es/hour Dynamic Combustion on
Interconnecti
45 Air_Temperature Air Temperature (Input) deg C Dynamic Combustion on
Interconnecti
46 Arch Pressure Arch Pressure (Input) barg Dynamic Combustion on
Interconnecti
47 Flue Gas Ash Flue Gas Ash Dynamic Combustion on
Flue Gas Carbon Flue Gas Carbon Interconnecti
48 DiOxide DiOxide (Output) Dynamic Combustion on
Flue Gas Carbon Flue Gas Carbon Interconnecti
49 Monoxide Monoxide (Output) Dynamic Combustion on
Flue Gas Mass Flue Gas Mass Flow Interconnecti
50 Flow (Output) kg/hr Dynamic Combustion on
Flue Gas Nitrogen Interconnecti
51 Flue Gas Nitrogen (Output) Dynamic Combustion on
Flue Gas Sulphur Flue Gas Sulphur Interconnecti
52 Dioxide Dioxide (Output) Dynamic Combustion on
Flue Gas Water Interconnecti
53 Flue Gas Water (Output) Dynamic Combustion on
Ash Mole Percent in Interconnecti
54 Fuel Ash Fuel (Input) % Dynamic Combustion on
Interconnecti
55 Carbon Carbon in fuel % Dynamic Combustion on
Hydrogen Mole Percent Interconnecti
56 Fuel Hydrogen in Fuel (Input) % Dynamic Combustion on
Fuel Inlet Mass Fuel Inlet Mass Flow Interconnecti
57 Flow (Input) kg/hr Dynamic Combustion on
Nitrogen Mole Percent Interconnecti
58 Fuel Nitrogen in Fuel (Input) % Dynamic Combustion on
Oxygen Mole Percent in Interconnecti
59 Fuel Oxygen Fuel (Input) % Dynamic Combustion on
Fuel Sensible Heat Interconnecti
60 Fuel Sensible Heat (Output) kJ/hr Dynamic Combustion on
Interconnecti
61 Fuel Sulphur Fuel Sulphur (Input) % Dynamic Combustion on
Inlet1_HeatCredit
(Asset Connection Interconnecti
62 Inlet1_HeatCredit Input) kJ/hr Dynamic Combustion on

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 Inlet1_FlowRate (Asset Interconnecti
63 Inlet1_FlowRate Connection Input) kg/hr Dynamic Combustion on
Interconnecti
64 Inlet2 Static Combustion on
Inlet2_HeatCredit
(Asset Connection Interconnecti
65 Inlet2_HeatCredit Input) kJ/hr Dynamic Combustion on
Inlet2_FlowRate (Asset Interconnecti
66 Inlet2_FlowRate Connection Input) kg/hr Dynamic Combustion on
Interconnecti
67 Inlet3 Static Combustion on
Inlet3_HeatCredit
(Asset Connection Interconnecti
68 Inlet3_HeatCredit Input) kJ/hr Dynamic Combustion on
Inlet3_MassFlow (Asset Interconnecti
69 Inlet3_MassFlow Connection Input) kg/hr Dynamic Combustion on
ProcessIn (Asset Interconnecti
70 ProcessIn Conection) Static Combustion on
Interconnecti
71 Stack NOx Stack NOx (Input) Dynamic Combustion on

Model Output data

S Attribute Monitoring
Attribute Description Units Source
No Category Category

Air To Fuel Air To Fuel Ratio

1 Ratio (Output) Dynamic Performance Calculated
Energy
2 Loss Energy Loss (Output) kJ/hr Dynamic Energy Calculated
Excess Air
3 Percentage % Excess Air (Output) % Dynamic Performance Calculated
Fuel
4 Efficiency Fuel Efficiency (Output) % Dynamic Performance Calculated
Furnace
5 Duty Furnace Duty (Output) megawatts Dynamic Performance Calculated
Heat
6 Credits Heat Credits (Output) kJ/kg-C Dynamic Energy Calculated
Heat
7 Losses Heat Losses (Output) kJ/hr Dynamic Energy Calculated
Thermal Thermal Efficiency
8 Efficiency (Output) % Dynamic Performance Calculated

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Configuring a Furnace Asset in Uniformance Asset Sentinel
To configure a furnace asset with performance model

Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter
Combustor.

Refer to the following procedures:

o To configure asset connection attributes.
o To map a dynamic attribute to the datasource tags.
o To set the attribute properties for the Attribute Viewer and Performance Overview.
o To manually update asset attribute information.

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 Steam Turbine Monitoring

Steam turbine is used in connection with industrial processes where there is a need for low or medium
pressure steam. Turbine stages consists of stationary stator row (guide vanes or nozzle ring) and
rotating rotor row. In the guide vanes high pressure, high temperature steam is expanded resulting in
high velocity. The guide vanes direct the flow to the rotor blades at an appropriate angle. In the rotor, the
flow direction is changed, and kinetic energy of the working fluid is absorbed by the rotor shaft
producing mechanical energy. The mechanical energy is used to run an electric generator or mechanical
equipment such as pump, fans, compressors etc.

Steam turbines are energy intensive equipment and by using performance monitoring tools, energy can
be saved by operating the steam turbine at desired operating conditions. Therefore, the availability of
steam turbine is an extremely important factor. Special monitoring system is required for monitoring
steam turbine performance to increase the availability and decrease the energy costs.

Monitoring basic machine health data in addition to Turbine operating conditions helps to maintain
reliable operations of a turbine. There are three areas that helps to monitor compressor performance to
increase the availability and decrease the energy costs.
o Process and condition monitoring
o Energy monitoring
o Performance and Health monitoring

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Individually, each of these important indicators collectively, they provide a complete picture as to the
actual condition of the steam turbine. This document explains Steam Turbine monitoring philosophy for
process, performance, energy and health parameters and their importance.

Item Type
Category Equipment
Equipment Class Turbine
Equipment Type Steam Turbine (Constant
Speed/Variable Speed)

Following are the types of Steam Turbine which are supported in this UAS template:
o Steam Turbine - Constant speed
o Steam Turbine - Variable Speed

10.1 Process Performance Monitoring

The following measured parameters are monitored as they have impact on performance and health of
back pressure steam turbine, if not maintained in operating range.

Inlet Steam Flow: Depending on load turbine steam inlet flow rate should be maintained. Normally a
flow controller is in place to control loading of turbine.

Inlet Steam Pressure: Steam turbines are designed to operate in range of supply pressure. Drop in
steam pressure can lead to trip scenario.

Inlet Steam Temperature: Steam temperature should be sufficiently more than saturation temperature
at given supply pressure as it may lead to water droplet formation inside turbine and lead to damage of
turbine blades.

Outlet Steam Pressure: In Back pressure turbine outlet steam pressure is maintained to supply MP/LP
steam to process plant.

Outlet Steam Temperature: Back pressure turbine outlet steam temperature is monitored to ensure that
condensation is not happening inside turbine.

Speed: Speed is direct indication of load or supply flow to a turbine.

Process Performance Overview: Process Performance monitoring view in UAS provides a list of the
asset attributes and their details, including the current value. This list can be used to review and update
asset attribute information, as well as to open an Asset Trend to view more details. It also highlights (in
red color) the attributes if deviates from the high or low limits.

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10.2 Energy Monitoring
Energy Monitoring includes monitoring of specific KPIs to optimize the energy consumption by steam
turbine.

Operating Specific Steam Consumption(kg/hr/kW): The actual steam rate of a turbine can be
determined by dividing the actual throttle steam flow rate (kg per hour) by the actual corresponding
energy (kilowatts), at the generator terminals, produced by that amount of steam. The resulting steam
rate is expressed in kg of steam per kWh. The actual steam rate can also be determined by dividing the
theoretical steam rate by the engine efficiency of the turbine generator.

Operating Exhaust Quality: Turbine output power is strongly affected by exhaust steam quality.
Exhaust steam quality is affected not only by condenser pressure, but also inlet superheat, inlet pressure
and turbine efficiency as well as turbine load. However, as exhaust steam quality declines, the potential
for blade damage in the lower pressure stages is also higher it's probably a nonlinear relationship.

10.3 Performance Monitoring

The effective utilization of the equipment can be monitored with the help of performance indicators.

Key Performance Indicators

The following indicators are key to know overall performance of the Steam Turbine. The current model is
built based on the working philosophy of Backpressure Turbine. In the Backpressure type turbine steam

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Model Library Guide 96
enters the turbine chamber at high pressure and expands to lower pressure. Enthalpy difference
between inlet and outlet steam is used for generating power/work.

Isentropic Efficiency = (H1-H2) / (H1-H2is)

Also, F1 = F2 (kg/hr)

Power generated from turbine = (H1-H2) * F1 * (2.77*10^-7) MW

Where, H1, H2 are the enthalpy of steam at the inlet and outlet conditions respectively, in kJ/kg.

F1, F2 are the steam flow rate at inlet and outlet.

H2is = isentropic enthalpy of exhaust steam.

H1, H2 and H2is can be estimated by using thermo properties available in UAS.

The enthalpy of exhaust steam at saturated condition has to be corrected for wetness of the steam. The
exact dryness factor is estimated by trial & error method. In this method, the dryness factor is varied to
match the total Power delivered by the turbine to drive a compressor or a pump.

The power produced from turbine generator coupled with generator efficiency and enthalpy difference
between supply and exhaust steam. In case the turbine is used to drive the rotating equipment’s like
compressor or pump then, power produced by turbine will be derived considering mechanical efficiency.

Operating Shaft Power

his measures steam turbine shaft power. It is set equal to the shaft power from the load of driving
equipment, if it loaded to equipment (like, compressor or pump). Or it is power produced by the
generator, if it drives generator set.

Operating Specific Steam Consumption

Represents the steam rate consumed per unit operating shaft power (Kg/hr/KW).

Performance Overview
Equipment Key Performance Indicators (KPIs) view in UAS provides a list of KPIs and their details,
including the current value. This list can be used to review and update asset attribute information, as
well as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if
deviates from the high or low limits.

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10.4 Failure Modes
In UAS, a fault model is built to identify possible anomalies that affects the performance or health of a
Steam Turbine. The fault management can inform operators of any violations of the nominal Steam
Turbine operating range and deviations from the expected characteristic and make this data available
for further processing through the historian.

The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions
o Operating Efficiency Low: Occurs due to variation in temperatures at inlet and outlet. It can be
avoided by operating the steam turbine at optimal conditions"
o Steam Exhaust Quality Low: High quality steam ensures steam is in gaseous state. Whereas low
quality steam comprises of mixture of liquid and vapor part. The liquid part of steam may erode the
turbine blades due to the turbine exit pressure being lower than the vapor pressure of liquid part,
causes liquid to form bubbles, and repeated hitting of these bubbles on turbine blades leads to
pitting. So, to avoid cavitation on turbine blades, and to have smooth flow, it is made sure that steam
exiting the turbine is of high quality.
o Steam Exhaust Pressure High: High pressure of exhaust steam causes the exiting steam to be
hotter and denser that it would be at a lower backpressure, which puts stress on the turbine blades at
exit. If the pressure increases the more the alarm limit, the turbine will normally trip off-line
o Inlet Steam Temperature Low: The steam Temperature should be high to increase the high quality
exhaust steam and the power output of the turbine. Hence the temperature should be monitored
against a limit to optimize performance of steam turbine.
o Inlet Steam Flowrate deviations: It is required to optimize the flow conditions to meet ideal
operating conditions and to achieve high efficiency. Hence monitoring inlet steam within limits is
important for efficient operation of a steam turbine.

Below table illustrates the list of faults and symptoms configured for a Steam Turbine.

Fault
Fault Name Associated Symptoms
Category
Operating Efficiency Low
Performance Performance Degradation Warning
Steam Exhaust Quality Low

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 Fault
Fault Name Associated Symptoms
Category
Steam Exhaust Pressure High
Inlet Steam Pressure Low
Inlet Steam Temperature Low
Inlet Steam Rate Low
Energy Energy Consumption High Outlet Steam Temperature High
Inlet Steam Flow High

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

10.5 Configuration
The calculation model to perform as expected, it requires some inputs are to be feed into the model. The
Steam Turbine model input data consists of measured data and static data. Measured input data is
supplied to the model from DCS or Historian by tag mapping. This section describes the list of input and
output attributes and its properties.

Model Input data

S Attribute Monitoring
Attribute Description Units Source
No Category Category

Inlet Steam Inlet Steam Mass Flow Field

1 Mass Flow Rate Rate (Required Input) barg Dynamic Process Input

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 S Attribute Monitoring
Attribute Description Units Source
No Category Category

Inlet Steam Inlet Steam Pressure Field

2 Pressure (Required Input) deg C Dynamic Process Input
Inlet Steam Inlet Steam Temperature Field
3 Temperature (Required Input) m3/hr Dynamic Process Input
Measured Shaft Measured Shaft Power Field
4 Power (Input) barg Dynamic Process Input
Operating
Exhaust Operating Exhaust Field
5 Temperature Temperature (Output) deg C Dynamic Process Input
Outlet Steam Outlet Steam Pressure Field
6 Pressure (Required Input) Dynamic Process Input
Outlet Steam
Temperature (Required
Outlet Input, if back-pressure
SteamTemperat exhaust option is Field
7 ure selected) rpm Dynamic Process Input
Field
Running Status of Asset Input/Cal
8 Running Status (Input) m Static Process culated
Steam Turbine Measured Steam Turbine Field
9 Speed Speed (Required Input) kW Dynamic Process Input
Constant
/Interpol
ated from
Barometric Barometric Pressure curve
10 Pressure (Input) bara Dynamic Design data
Constant
/Interpol
Default Exhaust Quality of ated from
Default Exhaust Steam (Input between 0.0 curve
11 Quality and 1.0) Static Design data
Constant
/Interpol
ated from
Mechanical Efficiency curve
12 Mech Efficiency (Input) % Static Design data
Constant
/Interpol
ated from
Rated Inlet Rated Inlet Pressure curve
13 Pressure (Input) bara Static Design data
Constant
/Interpol
Rated Inlet Rated Inlet Temperature ated from
14 Temperature (Input) deg C Static Design curve

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 S Attribute Monitoring
Attribute Description Units Source
No Category Category
data

Constant
/Interpol
ated from
curve
15 Rated Power Rated Power (Input) kW Static Design data
Constant
from
Manufac
turer
datashee
16 Rated Speed Rated Speed (Input) rpm Static Design t
Constant
Steam Exhaust Type from
(Input as 1-for Manufac
condensate exhaust, 2- turer
Steam Exhaust for back-pressure datashee
17 Type exhaust) Static Design t

Model Output data

S Attribute Monitoring
Attribute Description Units Source
No Category Category

Design
1 SteamRate Design Actual Steam Rate (Output) kg/hr/kW Dynamic Design Calculated
Design
2 Efficiency Design Efficiency (Output) % Dynamic Design Calculated
Design
Exhaust Design Exhaust Quality of Steam
3 Quality (Output) Dynamic Design Calculated
Design
Exhaust
4 Temperature Design Exhaust Temperature (Output) deg C Dynamic Design Calculated
Design
Mech Design Mechanical Efficiency
5 Efficiency (Output) % Dynamic Design Calculated
Design Shaft
6 Power Design Shaft Power (Output) kW Dynamic Design Calculated

Design
Transpose Design Transpose Steam Rate
7 SteamRate (Output) kg/hr/kW Dynamic Design Calculated

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 S Attribute Monitoring
Attribute Description Units Source
No Category Category

Ideal Steam
8 Rate Ideal Steam Rate (Output) kg/hr/kW Dynamic Design Calculated
Operating
Mech Operating Mechanical Efficiency
10 Efficiency (Output) % Dynamic Design Calculated

Operating
Actual
11 SteamRate Operating Actual Steam Rate (Output) kg/hr/kW Dynamic Performance Calculated

Operating
12 Efficiency Operating Efficiency (Output) % Dynamic Performance Calculated

Operating
Exhaust Operating Exhaust Quality of Steam
13 Quality (Output) Dynamic Performance Calculated

Operating
14 Shaft Power Operating Shaft Power (Output) kW Dynamic Performance Calculated

Operating
Transpose Operating Transpose Steam Rate
15 SteamRate (Output) kg/hr/kW Dynamic Performance Calculated

Actual Percent Deviation in Actual Steam

SteamRate Rate between Operating and Design
16 % Deviation values (Output) % Dynamic Deviation Calculated

Percent Deviation in Shaft Power

Shaft Power between Operating and Design values
17 % Deviation (Output) % Dynamic Deviation Calculated

Transpose Percent Deviation in Transpose Steam

SteamRate Rate between Operating and Design
18 % Deviation values (Output) Dynamic Deviation Calculated

Efficiency Deviation in Efficiency between

19 Deviation Operating and Design values (Output) Dynamic Deviation Calculated

Exhaust Deviation in Exhaust Quality of Steam

Quality between Operating and Design values
20 Deviation (Output) Dynamic Deviation Calculated

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 S Attribute Monitoring
Attribute Description Units Source
No Category Category

Exhaust Deviation in Exhaust Temperature

Temperature between Operating and Design values
21 Deviation (Output) Dynamic Deviation Calculated

Configuring a Steam Turbine Asset in Uniformance Asset

Sentinel
To configure a Steam Turbine asset

Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter Steam
Turbine- Variable Speed.

Refer to the following procedures:

o To configure asset connection attributes.
o To map a dynamic attribute to the datasource tags.
o To set the attribute properties for the Attribute Viewer and Performance Overview.
o To manually update asset attribute information.

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 Shell and Tube Heat Exchanger
Monitoring

Heat Exchanger is an equipment used to transfer heat from one fluid to another fluid, which are
separated by a solid wall. This is mainly used to exchange the heat between two fluids for heating,
cooling, or waste heat recovery.

Shell and Tube Heat Exchanger (STHE) consists of a shell (a large pressure vessel) with a bundle of
tubes inside it. The set of tubes is called a tube bundle. Two fluids of different starting temperatures flow
through the heat exchanger in which one fluid runs through the tubes and the other fluid flows over the
tubes (through the shell) to transfer heat between two fluids. Heat exchanger performance monitoring
plays an important role to predict the cleaning and maintenance schedules with fouling, tube damage,
and leakage. Monitoring basic machine health data in addition to Heat Exchanger operating conditions
helps to maintain reliable operations of a Heat Exchanger. There are two areas that helps to monitor
Heat Exchanger performance to increase the availability and decrease the energy costs.
o Process and condition monitoring
o Performance and Health monitoring

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Individually, each of these important indicators collectively, they provide a complete picture as to the
actual condition of the Shell and Tube Heat Exchanger. This document explains Heat Exchanger
monitoring philosophy for process, performance, energy and health parameters and their importance.

Item Type
Category Equipment
Equipment Class Heat Exchanger
Equipment Type Shell and Tube

11.1 Process Performance Monitoring

The following measured parameters are monitored as they have impact on performance and health of
shell and tube exchanger, if not maintained in operating range.

Shell/Tube Inlet Temperature: The increase or decrease of the inlet temperature will affect the heat
transfer within the heat exchanger and thereby varies the outlet temperature.

Shell/tube Mass/Volumetric flow rate: The increase in the flow rate of fluids results in increase in the
film heat transfer coefficient and thereby increase in the expected overall heat transfer coefficient.

Shell/Tube Inlet Pressure: The increase or decrease in pressure can vary parameters like temperature,
velocity of flow etc., which ultimately may affect convective heat transfer coefficient.

Process Performance Overview: Process Performance monitoring view in UAS provides a list of the
asset attributes and their details, including the current value. This list can be used to review and update
asset attribute information, as well as to open an Asset Trend to view more details. It also highlights (in
red color) the attributes if deviates from the high or low limits.

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11.2 Performance Monitoring
Performance of the Shell and Tube Heat Exchanger can be monitored with the help of performance
indicators which ensures the effective utilization of the equipment.

Key Performance Indicators

The following indicators help us to know overall performance of the Shell and Tube Heat Exchanger.

Operating Effectiveness
This is defined as the ratio of the actual heat transfer to the maximum possible heat transfer rate for the
given flow and temperature conditions. Operating Effectiveness for a heat exchanger can be explained
in four different cases.

Case 1: For Co-Current flow, where product of mass flow rate and mass specific heat capacity for hot
fluid is minimal.

(OT1 - OT2)

Operating Effectiveness = (OT1 - Ot1)

Where, OT1 = Operating Hotside Inlet temperature (Deg C, K)

OT2 = Operating Hotside Outlet temperature (Deg C, K)

Ot1 = Operating Coldside Inlet temperature (Deg C, K)

Case 2:

For Co-Current flow, where product of mass flow rate and mass specific heat capacity for cold fluid
minimal.

(Ot2 – Ot1)

Operating Effectiveness = (OT1 - Ot1)

Where, OT1 = Operating Hotside Inlet temperature (Deg C, K)

Ot1 = Operating Coldside Inlet temperature (Deg C, K)

Ot2 = Operating Coldside Outlet temperature (Deg C, K)

Case 3:

For Counter-Current flow, where product of mass flow rate and mass specific heat capacity for hot fluid
minimal

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 (OT1 - OT2)

Operating Effectiveness = (OT1 - O t2)

Where, OT1 = Operating Hotside Inlet temperature (Deg C, K)

OT2 = Operating Hotside Outlet temperature (Deg C, K)

Ot2 = Operating Coldside Outlet temperature (Deg C, K)

Case 4:

For Counter-Current flow, where product of mass flow rate and mass specific heat capacity for cold fluid
minimal

(Ot2 – Ot1)

Operating Effectiveness = (OT1 - Ot2)

Where, OT1 = Operating Hotside Inlet temperature (Deg C, K)

Ot1 = Operating Coldside Inlet temperature (Deg C, K)

Ot2 = Operating Coldside Outlet temperature (Deg C, K)

Expected Effectiveness
This is defined as the ratio of the expected heat transfer to the maximum possible heat transfer rate for
the given flow and temperature conditions. Expected Effectiveness for a heat exchanger can be
explained in four different cases

Case 1:

For Co-Current flow, where product of mass flow rate and mass specific heat capacity for hot fluid
minimal.

(OT1 - ET2)

Expected Effectiveness = (OT1-Ot1)

Where, OT1 = Operating Hotside Inlet temperature (Deg C, K)

ET2 = Expected Hotside Outlet temperature (Deg C, K)

Ot1 = Operating Coldside Inlet temperature (Deg C, K)

Case 2:

For Co-Current flow, where product of mass flow rate and mass specific heat capacity for cold fluid
minimal.

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 (Et2 - Ot1)

Expected Effectiveness = (OT1- Ot1)

Where, OT1 = Operating Hotside Inlet temperature (Deg C, K)

Et2 = Expected Coldside Oulet temperature (Deg C, K)

Ot1 = Operating Coldside Inlet temperature (Deg C, K)

Case 3:

For Counter-Current flow, where product of mass flow rate and mass specific heat capacity for hot fluid
minimal.

(OT1 - ET2)

Expected Effectiveness = (OT1-Ot2)

Where, OT1 = Operating Hotside Inlet temperature (Deg C, K)

ET2 = Operating Hotside Outlet temperature (Deg C, K)

Ot2 = Operating Coldside Outlet temperature (Deg C, K)

Case 4:

For Counter-Current flow, where product of mass flow rate and mass specific heat capacity for cold fluid
minimal.

(Et2 – Ot1)

Expected Effectiveness = (OT1-Ot2)

Where, OT1 = Operating Hotside Inlet temperature (Deg C, K)

Et2 = Expected Coldside Outlet temperature (Deg C, K)

Ot2 = Operating Coldside Outlet temperature (Deg C, K)

Effectiveness Deviation
This KPI represents the deviation of Operating effectiveness with Expected Effectiveness at current
operating conditions.

% Effectiveness Deviation = ((Operating effectiveness -Expected effectiveness)/Expected effectiveness

*100

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Operating Duty
The amount of energy transferred from one fluid to another within the exchanger, it is calculated using,
mass flow, temperature sensors of both Shell and tube side and effective surface area. It is average of
the Shell and Tube Side Duty.

Operating Duty Q = Average (Shell side Duty and Tube Side Duty)

Shell Side Duty QS = Ms*CpS* TS

Where, Ms = Mass flow rate of shell side fluid.

CpS = Specific heat of Shell side fluid.

TS = Shell side temperature difference

Tube Side Duty QT = MT*CpT* TT

Where, MT = Mass flow rate of Tube side fluid.

CpT = Specific heat of Tube side fluid.

TT = Tube side temperature difference.

Heat Transfer Coefficient

Heat transfer coefficient is a quantitative characteristic of convective heat transfer between a fluid
medium (a fluid) and the surface (wall) flowed over by the fluid. Two types of heat transfer coefficient are
monitored for performance.

Operating Heat transfer coefficient.

Expected Overall Heat transfer coefficient.

Operating Heat transfer coefficient

Operating Heat transfer coefficient is calculated at current operating conditions as follows.

Operating HTC= Overall Duty/ (Design Heat Transfer Area*Operating LMTD)

Where, Operating LMTD = TTM * FT

Log mean temperature difference TTM = (T1-t2) – (T2-t1)

Ln((T1-t2) / (T2-t1))

Where, T1 = inlet temperature of the shell-side (or hot) fluid

T2= exit temperature of the shell-side (or hot) fluid

t1 = inlet temperature of the tube-side (or cold) fluid

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 t2 = exit temperature of the tube-side (or cold) fluid

LMTD correction factor FT = ((SQRT(R^2+1)/(R-1)) *LN((1-x)/(1-R*x)))/LN((2/x-1-

R+SQRT(R^2+1))/(2/x-1-R-SQRT(R^2+1)))

R = (T1-T2) – (t2-t1)

P = (t2-t1) – (T1-t1)

X = (1 - ((R*P-1)/(P-1)) ^(1/N))/ (R - ((R*P-1)/(P-1)) ^(1/N))

Where, N = Number of Shell side passes

Expected Overall Heat transfer coefficient

It is the expected heat transfer coefficient at current operating condition when there is no fouling.

It is calculated by two methods:

NTU based method

This method is suitable for situations when shell and tube side film heat transfer coefficient values are
not available from the datasheet. NTU to be given as manual input to calculate expected heat transfer
coefficient.

NTU Based Expected overall HTC= NTU*Min (MT*CpT, MS * CpS)/AE

Where, MT = Mass flow rate of Tube side fluid.

CpT = Specific heat of Tube side fluid.

MS = Mass flow rate of shell side fluid.

CpS = Specific heat of shell side fluid.

AE = Effective Surface Area.

Fouling Resistance based method

FR Based Expected Overall HTC = 1/ totFR*(A / AE)

Where, totFR = Total Fouling resistance

A = Surface Area

AE = Effective Surface Area

HTCT = HTCFT* (MT / MRT) CFHTC

HTCS = HTCFS *(MS / MRS) CFHTC

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0.8 is default power factor (CFHTC) used in UAS standard heat exchanger template. However, it can be
changed with the attribute “HTCCorrectionFactor”.

ratFR = FRRT (ODT/ IDT) + FRRS

totFR = 1 / HTCS + 1 / HTCT * (ODT/ IDT) + TWT / Kw + ratFR

Where, HTCT = Mass flow rate of Tube side fluid.

HTCS = Rated tube side mass flow rate.

HTCFT = Tube side film HTC.

HTCFS = Shell side film HTC.

CFHTC= HTC correction factor

MT = Mass flow rate of Tube side fluid.

MRT = Rated tube side mass flow rate.

MS = Mass flow rate of shell side fluid.

MRS = Rated shell side mass flow rate.

ratFR = Rated friction factor.

ODT = Tube outside Diameter.

IDT = Tube inside Diameter.

FRRS = Rated Shell Fouling Resistance.

FRRT = Rated Tube Fouling Resistance.

TWT = Tube wall thickness.

Kw = Tube wall thermal conductivity.

Tube Side Delta P

Tube side Delta P is the difference between the Tube inlet and Outlet pressure. In general, fouling and
corrosive liquids are routed through tube side as they are comparatively easy to replace. The rise in
pressure drop on tube side indicates fouling.

Tube Side P = (Tubeside outlet Pressure – Tubeside inlet Pressure)

Fouling Percentage
Fouling Percentage is the amount of exchanger fouled with respect to current and clean heat transfer
coefficient. Fouling percentage

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Fouling Percentage= (1-(Operating HTC/ExpectedHTC)) *100

The design performance is determined by the rated fouling resistance of the shell and tube heat
exchanger. The expected overall heat transfer coefficient is calculated from the rated fouling resistance.
The design shell side outlet temperature and tube side outlet temperature are calculated by using
measured flow rates, shell side inlet temperature, tube side inlet temperature, and expected overall heat
transfer coefficient. The other expected calculation like design effectiveness, design duty, design LMTD
and so on are calculated using the design shell side outlet temperature and tube side outlet
temperature. This section describes the list of input and output attributes and its properties.

Performance Overview
Equipment Key Performance Indicators (KPIs) view in UAS provides a list of KPIs and their details,
including the current value. This list can be used to review and update asset attribute information, as
well as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if
deviates from the high or low limits.

11.3 Failure Modes

In Uniformance Asset Sentinel, faults, symptoms, and fault models are configured based on Heat
Exchanger performance model outputs and process Parameters measured from field to diagnose the
problems early. The fault management can inform operators of any violations of the nominal Heat
Exchanger operating range and deviations from the expected characteristic and make this data
available for further processing through the historian. The fault symptoms or models are used to:
o Warn against potential damage to Heat Exchanger under unfavorable operating conditions.
o Provide early warning of damages to the Heat Exchanger.

The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions
o Heat transfer degradation: occurs mainly due to fouling and leakage in heat exchanger.

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 o Low effectiveness: occurs due to variation in temperatures at inlet and outlet. It can be avoided by
operating the heat exchanger at optimal conditions.
o Leakage: It can be detected by checking the material balance.
o Possible damage to pipes: The most probable cause is debris in the fuel nozzles. This results in
very less combustor efficiency and less turbine inlet temperature.
o Fouling: It is an important factor in heat exchangers, caused due to deposition of material on the
Heat transfer surfaces. The heat exchanger effective heat duty and heat transfer coefficient
decreases when fouling occurs. Fouling predictions are used to predict the maintenance schedules
for cleaning heat exchanger.

Below table illustrates the list of faults and symptoms configured for a Shell and Tube Heat Exchanger.

Fault Category Fault Name Associated Symptoms

Shell Outlet Temperature Deviation

High
Health Shell Side Fouling Shell Side DP Deviation High
High Tube Outlet Temp
Health Tube Side Fouling High Tube Side DP
High Fouling Percentage
Low HTC
Low Effectiveness
Performance Performance Degradation High Fouling Resistance

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

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11.4 Configuration
The purpose of the shell and tube heat exchanger model is to determine the operating, design, and
deviation performance. The operating performance of a heat exchanger is determined using measured
input data supplied to the condition analysis program through the site instrumentation and historian.
The operating performance is calculated for each set of measured input data. In addition to the
measured input data, a number of model parameters must also be supplied by the user through the user
interface.

Model Input data

Attribute Monitoring
S No Attribute Description Units Source
Category Category

Running Operational Status of

1 Status Asset (Input) Dynamic Process Field Input
Shell Side Inlet Fluid
Density (Required
Input, if shell fluid
Shell Inlet property data is not Thermo
2 Fluid Density given) kg/m3 Dynamic Properties Field Input
Shell Side Inlet Fluid
Specific Heat
(Required Input, if
Shell Inlet shell fluid property kJ/kg- Thermo
3 Fluid SpHeat data is not given) C Dynamic Properties Field Input

Shell Side Fluid Inlet

Shell Inlet Temperature (Required
4 Temperature Input) deg C Dynamic Process Field Input
Shell Inlet Shell Side Fluid Inlet
Volume Volume Flow Rate
5 FlowRate (Required Input) m3/hr Dynamic Process Field Input
Shell Inlet Shell Inlet Pressure
6 Pressure (Input) barg Dynamic Process Field Input
Shell Side Fluid Outlet
Temperature (Required
Input, if Tube side fluid
Shell Outlet outlet temperature is
7 Temperature not given) deg C Dynamic Process Field Input

Shell Outlet Shell Outlet Pressure

8 Pressure (Input) barg Dynamic Process Field Input
Tube Side Inlet Fluid
Density (Required
Input, if tube fluid
Tube Inlet property data is not Thermo
9 Fluid Density given) kg/m3 Dynamic Properties Field Input

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 Attribute Monitoring
S No Attribute Description Units Source
Category Category

Tube Side Inlet Fluid

Specific Heat
(Required Input, if tube
Tube Inlet fluid property data is kJ/kg- Thermo
10 Fluid SpHeat not given) C Dynamic Properties Field Input

Tube Side Fluid Inlet

Tube Inlet Temperature (Required
11 Temperature Input) deg C Dynamic Process Field Input
Tube Inlet Tube Side Fluid Inlet
Volume Volume Flow Rate
12 FlowRate (Required Input) m3/hr Dynamic Process Field Input
Tube Inlet Tube Inlet Pressure
13 Pressure (Input) barg Dynamic Process Field Input
Tube Side Fluid Outlet
Temperature (Required
Input, if Shell side fluid
Tube Outlet outlet temperature is
14 Temperature not given) deg C Dynamic Process Field Input
Tube Outlet Tube Outlet Pressure
15 Pressure (Input) barg Dynamic Process Field Input
Effective Surface Area
Effective for heat transfer
16 Surface Area (Input) m2 Static Design Constant
CounterCurrent =
1,CoCurrent =
2,CrossFlowShell =
3,CrossFlowTube =
4,BothSideCrossFlow =
17 Flow Direction 5 Static Design Constant

Coeff for HTC

correction based on
HTC mass flow change 0-
18 Correction 1.0(Optional) Dynamic Design Constant
Design NTU to
estimate design
HTC (Required Input
19 Rated NTU if spec is non zero) Static Design Constant
Rated Shell Rated Shell Side
Fouling Fouling Resistance m2-hr-
20 Resistance (Input) C/kJ Static Design Constant
Rated Shell Rated Shell Side Fluid
21 Mass Rate Mass Rate (Input) kg/hr Static Design Constant
22 Rated Tube Rated Tube Side m2-hr- Static Design Constant

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Model Library Guide 115
 Attribute Monitoring
S No Attribute Description Units Source
Category Category
Fouling Fouling Resistance C/kJ
Resistance (Input)
Rated Tube Rated Tube Side Fluid
23 Mass Rate Mass Rate (Input) kg/hr Static Design Constant
# of shell pass:(1) 1
Shell 2 Tube Tema
E;(2) 2 Shell 4 Tube
Tema E;(3) 3 Shell 6
Tube Tema E;(4) 4
Shell 8 Tube Tema
E;(5) 5 Shell 10 Tube
Tema E;(6) 6 Shell 12
Tube Tema E
24 Shell Pass (Required Input) Static Design Constant
0-default;1-
CalculateRatedHTC;2-
CalculateShellOutTem
p,CalculateTubeOutTe
mperature (Optional
25 Specification Input) Dynamic Design Constant
Total Surface Total Surface Area
26 Area (Required Input) m2 Static Design Constant
Tube Outside Tube Outside Diameter
27 Diameter (Required Input) m Static Design Constant
Tube Wall Tube Wall Thickness
28 Thickness (Required Input) m Static Design Constant
Tube Wall Thermal
Wall Thermal Conductivity (Required kJ/m-
29 Conductivity Input) hr-C Static Design Constant

Model Output data

S Attribute Monitoring
Attribute Description Units Source
No Category Category

Design Heat Duty

1 Design Duty (Output) kJ/hr Dynamic Design Calculated

Design
Design Effectiveness
2 Effectiveness (Output) % Dynamic Design Calculated

Design
Fouling Design Fouling m2-hr-
3 Resistance Resistance (Output) C/kJ Dynamic Design Calculated

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 S Attribute Monitoring
Attribute Description Units Source
No Category Category

Design Log Mean

Temperature
4 Design LMTD Difference (Output) deg C Dynamic Design Calculated
Design Overall Heat
Design Overall Transfer Coefficient kJ/m2-
5 HTC (Output) hr-C Dynamic Design Calculated
Design Shell Side
Design Shell Outlet Temperature
6 Out Temp (Output) deg C Dynamic Design Calculated

Design Tube Side

Design Tube Outlet Temperature
7 Out Temp (Output) deg C Dynamic Design Calculated
Deviation
Effectiveness
between Operating
Deviation and Deisgn values
8 Effectiveness (Output) % Dynamic Design Calculated
Deviation Fouling
Resistance between
Deviation Operating and
Fouling Design values m2-hr-
9 Resistance (Output) C/kJ Dynamic Design Calculated

Deviation LMTD
between Operating
Deviation and Design values
10 LMTD (Output) deg C Dynamic Design Calculated
Deviation Overall
Heat Transfer
Coefficient between
Operating and
Deviation Design values kJ/m2-
11 Overall HTC (Output) hr-C Dynamic Design Calculated
Deviation Shell Side
Fluid Outlet
Temperature
Deviation between Operating
Shell Out and Design values
12 Temp (Output) deg C Dynamic Design Calculated
Deviation Tube Side
Fluid Outlet
Tempearture
Deviation between Operating
Tube Out and Design values
13 Temp (Output) deg C Dynamic Design Calculated

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 S Attribute Monitoring
Attribute Description Units Source
No Category Category

Percent Deviation
Heat Duty between
Operating and
Percent Design values
14 Deviation Duty (Output) % Dynamic Design Calculated
% of fouling
compared to design
Fouling fouling resistance
15 Percentage (Output) % Dynamic Performance Calculated
Operating Operating Heat Duty
16 Duty (Output) kJ/hr Dynamic Performance Calculated
Operating
Operating Effectiveness
17 Effectiveness (Output) % Dynamic Performance Calculated
Operating
Fouling Operating Fouling m2-hr-
18 Resistance Resistance (Output) C/kJ Dynamic Performance Calculated
Operating Log Mean
Operating Temperature
19 LMTD Difference (Output) deg C Dynamic Performance Calculated
Operating Overall
Operating Heat Transfer kJ/m2-
20 Overall HTC Coefficient (Output) hr-C Dynamic Performance Calculated
Shell Side Shell Side Pressure
21 Pressure Drop Drop(Output) bar Dynamic Performance Calculated
Tube Side Tube Side Pressure
22 Pressure Drop Drop(Output) bar Dynamic Performance Calculated

Configuring a Shell and Tube Heat Exchanger in

Uniformance Asset Sentinel
To configure Shell and Tube Heat Exchanger asset

Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter Shell
and Tube Heat Exchanger.

Refer to the following procedures:

o To configure asset connection attributes.
o To map a dynamic attribute to the datasource tags.
o To set the attribute properties for the Attribute Viewer and Performance Overview.
o To manually update asset attribute information.

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Uniformance® Asset Sentinel
Model Library Guide 119
 Cooling Tower Monitoring

A cooling tower is a specialized heat exchanger in which, air and water are brought into direct contact
with each other in order to reduce the water's temperature. During this process, a small volume of water
is evaporated by reducing the temperature of the water being circulated through the tower. Water heated
by an industrial process or in an air-conditioning condenser is pumped to the cooling tower through
pipes. The water sprays through nozzles and exposes as much water surface area as possible for
maximum air-water contact. As the water flows through the cooling tower, it is exposed to air, which is
being pulled through the tower by the electric motor-driven fan. When the water and air meet, a small
amount of water is evaporated, creating a cooling action. The cooled water is then pumped back to the
condenser or process equipment where it absorbs heat. It will then be pumped back to the cooling tower
to be cooled once again.

Cooling towers are a very important part of many chemical plants. Cooling tower performance
monitoring plays an important role to predict the cleaning and maintenance schedules with fouling,
scaling, leakage etc. Monitoring Basic machine health data in addition to Cooling tower operating
conditions helps to maintain reliable operations of a Cooling tower. There are two areas that helps to
monitor Cooling tower performance to increase the availability and decrease the energy costs.
o Process and condition monitoring
o Performance and Health monitoring

This document explains Cooling tower monitoring philosophy for process, performance, energy and
health parameters and their importance.

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Model Library Guide 120
 Item Type

Category Equipment
Equipment Class Heat Exchanger
Equipment Type Cooling Tower

12.1 Process Performance Monitoring

The following measured parameters are monitored as they have impact on performance and health of
Cooling tower, if not maintained in operating range.

Air Inlet Temperature (dry bulb)- The Dry Bulb temperature, usually referred to as air temperature. The
Dry Bulb Temperature refers basically to the ambient air temperature. It is called "Dry Bulb" because the
air temperature is indicated by a thermometer not affected by the moisture of the air.

Wet Bulb Temperature: Wet bulb temperature is an important factor in performance of evaporative
water-cooling equipment. It is a controlling factor from the aspect of minimum cold-water temperature
to which water can be cooled by the evaporative method. Thus, the wet bulb temperature of the air
entering the cooling tower determines operating temperature levels throughout the plant, process, or
system. Theoretically, a cooling tower will cool water to the entering wet bulb temperature, when
operating without a heat load.

Water Makeup Flow: As water evaporates in a cooling tower system, the water vapor enters the
atmosphere while any dissolved solids remain behind, building concentration in the remaining water.
Most water treatment systems control this concentration by bleeding off the high concentration water,
which is made up by fresh city water with a lower solid concentration.

Process Performance Overview: Process Performance monitoring view in UAS provides a list of the
asset attributes and their details, including the current value. This list can be used to review and update
asset attribute information, as well as to open an Asset Trend to view more details. It also highlights (in
red color) the attributes if deviates from the high or low limits.

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12.2 Performance Monitoring
Performance of the Cooling tower can be monitored with the help of performance indicators which
ensures the effective utilization of the equipment.

Key Performance Indicators

The following indicators help us to know overall performance of a Cooling tower.

Approach
Approach is the difference between the cooling tower outlet cold water temperature and ambient wet
bulb temperature.

Cycles of Concentration
Cycles of concentration is the ratio of dissolved solids in circulating water to the dissolved solids in
makeup water.

Range
It is the difference between the cooling tower water inlet and outlet temperature.

Evaporation Loss
Evaporation loss is the water quantity evaporated for cooling duty and, theoretically, for every
10,00,000-kCal heat rejected, evaporation quantity works out to 1.8 m3. An empirical relation used often
is:

Evaporation Loss (m3/hr) = 0.00085 x 1.8 x circulation rate (m3/hr) x (T1-T2)

T1-T2 = Temperature difference between inlet and outlet water.

Cooling Tower Efficiency

Cooling tower effectiveness (in percentage) is the ratio of range, to the ideal range, i.e., difference
between cooling water inlet temperature and ambient wet bulb temperature, or in other words it is =
Range / (Range + Approach).

Blow down loss

Blow down losses depend upon cycles of concentration and the evaporation losses and is given by
relation:

Blow Down = Evaporation Loss / (Cycles of Concentration – 1)

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Cooling Tower Duty
Cooling Tower Duty is the heat rejected in kCal/hr or TR, given as product of mass flow rate of water,
specific heat and temperature difference.

Performance Overview
Equipment Key Performance Indicators (KPIs) view in UAS provides a list of KPIs and their details,
including the current value. This list can be used to review and update asset attribute information, as
well as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if
deviates from the high or low limits.

12.3 Failure Modes

In Uniformance Asset Sentinel, faults, symptoms, and fault models are configured based on Cooling
tower performance model outputs and process Parameters measured from field to diagnose the
problems early. The fault management can inform operators of any violations of the nominal Cooling
tower operating range and deviations from the expected characteristic and make this data available for
further processing through the historian. The fault symptoms or models are used to:
o Warn against potential damage to Cooling tower under unfavorable operating conditions.
o Provide early warning of damages to the Cooling tower.

The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions
o High water loss: It is determined loss of water in terms of evaporation loss, drift loss, Blowdown
loss.
o Makeup water flow: It used to control the concentration of deposited solids in cooling tower. The
amount of water that is bled off by the water treatment system is usually less than or equal to the
amount of water that evaporates.

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 o Low Cooling Tower efficiency: It is determined by means of the deviation of the current cooling
tower efficiency from the design cooling tower efficiency.
o Heat transfer degradation: It occurs mainly due to fouling and leakage in heat exchanger.
o Low effectiveness: It occurs due to variation in temperatures at inlet and outlet. It can be avoided
by operating the cooling tower at optimal conditions.
o Fouling: It is an important factor in cooling tower, caused due to deposition of material on the fills.
The cooling tower effective heat duty and heat transfer coefficient decreases when fouling occurs.
Fouling predictions are used to predict the maintenance schedules for cleaning heat exchanger.

Below table illustrates the list of faults and symptoms configured for a Cooling Tower.

Fault Category Fault Name Associated Symptoms

Cooling Water Outlet Temp High

Water Loss High
Makeup Water Flow Low
Heat Transfer Efficiency Low
Performance Performance Degradation Cooling Tower Efficiency Low
Health Health Degradation Cooling Tower Fouling

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

12.4 Configuration
The purpose of the Cooling tower model is to determine the operating, design, and deviation
performance. The operating performance of a Cooling Tower is determined using measured input data
supplied to the condition analysis program through the site instrumentation and historian. The

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operating performance is calculated for each set of measured input data. In addition to the measured
input data, a number of model parameters must also be supplied by the user through the user interface.

Model Input data

S Attribute Monitoring
Attribute Description Units Source
No Category Category

Operational Status of
1 Running Status Dynamic Process Field Input
Asset (Input)
No of Running Actual No of Running
2 Dynamic Process Field Input
Fans Fans (Input)
Air Volume Air Volume FlowRate
3 m3/hr Dynamic Process Field Input
FlowRate (Required Input)
Air Inlet Air Inlet Pressure
4 barg Dynamic Process Field Input
Pressure (atmospheric)
Air Inlet
Air Inlet Temperature
5 Temperature deg C Dynamic Process Field Input
(Required Input)
(dry bulb)
Cooling Water Cooling Water Pressure
6 barg Dynamic Process Field Input
Pressure (Input)
Water
Water Blowdown
7 Blowdown kg/hr Dynamic Process Field Input
FlowRate (Required Input)
FlowRate
Wet Bulb Wet Bulb Temperature
8 deg C Dynamic Process Field Input
Temperature (Required Input)
Water
Water Circulation
9 Circulation kg/hr Dynamic Process Field Input
FlowRate (Required Input)
FlowRate
Water Makeup Water Makeup FlowRate
10 kg/hr Dynamic Process Field Input
FlowRate (Required Input)
Cold Water Cold Water Outlet pH
11 Dynamic Process Field Input
Outlet pH (Input)
Hot Water Inlet
Hot Water Inlet
12 Temperature (Required deg C Dynamic Process Field Input
Temperature
Input)
Cold Water Cold Water Outlet
13 Outlet Temperature (Required deg C Dynamic Process Field Input
Temperature Input)
Air Inlet Specific Heat
kJ/kg- Thermo
14 Air Inlet SpHeat (Required Input, if fluid Dynamic Field Input
C Properties
property data is not given)
Latent Heat (Required
Thermo
15 Latent Heat Input, if fluid property Dynamic Field Input
Properties
data is not given)
Actual Air Density
Actual Air Thermo
16 (Required Input, if fluid kg/m3 Dynamic Field Input
Density Properties
property data is not given)

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 S Attribute Monitoring
Attribute Description Units Source
No Category Category

Liquid to Gas Liquid to Gas Ratio

17 Static Design Constant
Ratio (Required Input)
Design / Rated Air Inlet
Design Air Inlet
18 Temperature (Required deg C Static Design Constant
Temperature
Input)
Design Rated Design / Rated Air Outlet
19 Air Outlet Temperature (Required deg C Static Design Constant
Temperature Input)
Rated Duty Per Rated Duty Per Fan
20 kW Static Design Constant
Fan (Required Input)
Rated Heat Rated Heat Duty
21 kW Static Design Constant
Duty (Required Input)
Design Hot Design / Rated Hot Water
22 Water Inlet Inlet Temperature deg C Static Design Constant
Temperature (Required Input)
Design Cold Design / Rated Cold
23 Water Outlet Water Outlet Temperature deg C Static Design Constant
Temperature (Required Input)
square
Heat Transfer Heat Transfer Area per _metre
24 Area per volume volume unit (Required s/cubi Static Design Constant
unit Input) c_metr
e
Heat Transfer Heat Transfer Volume cubic_
25 Static Design Constant
Volume (Required Input) meter
Hot Water Inlet Hot Water Inlet Specific kJ/k
26 Static Design Constant
Sp Heat Heat (Required Input) g-C
Water in Air Water in Air Loss Factor
27 % Static Design Constant
Loss Factor (Required Input)
Water Density (Required
28 Water Density kg/m3 Static Design Constant
Input)

Model Output data

S Attribute Monitoring
Attribute Description Units Source
No Category Category
Cooling Tower Cooling Tower
1 % Dynamic Performance Calculated
Efficiency Efficiency (Output)
Cooling Tower Cooling Tower Load
2 % Dynamic Performance Calculated
Load (Output)
Cooling Tower Cooling Tower Duty
3 kW Dynamic Performance Calculated
Duty (Output)
4 Range Range (Output) deg C Dynamic Performance Calculated

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 S Attribute Monitoring
Attribute Description Units Source
No Category Category
5 Approach Approach (Output) deg C Dynamic Performance Calculated
Cycles of
Cycles of
6 Concentration Dynamic Performance Calculated
Concentration
(Output)
7 Water Loss Water Loss (Output) m3/hr Dynamic Performance Calculated

Actual Heat Transfer

8 Actual HTC Dynamic Performance Calculated
Coefficient (Output)
kJ/m2-
hr-C
Expected No of
Expected No of
9 Running Fans Dynamic Performance Calculated
Running Fans
(Output)
Air Exhaust Air Exhaust
10 deg C Dynamic Energy Calculated
Temperature Temperature (Output)
Operating Log Mean
11 Operating LMTD Temperature deg C Dynamic Energy Calculated
Difference (Output)
Design Log Mean
12 Design LMTD Temperature deg C Dynamic Design Calculated
Difference (Output)
Humidity Ratio
13 Humidity Ratio Dynamic Energy Calculated
(Output)
Number of Transfer
14 NTU Dynamic Energy Calculated
Units (Output)
Blowdown Loss
15 Blowdown Loss m3/hr Dynamic Energy Calculated
(Output)
16 Drift Loss Drift Loss (Output) m3/hr Dynamic Energy Calculated
Evaporation Loss
17 Evaporation Loss m3/hr Dynamic Energy Calculated
(Output)
Expected Heat
kJ/m2-
18 Expected HTC Transfer Coefficient Dynamic Energy Calculated
hr-C
(Output)
Heat Transfer
Heat Transfer
19 Efficiency [%] % Dynamic Energy Calculated
Efficiency
(Output)

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Configuring a Cooling Tower in Uniformance Asset Sentinel
To configure a Cooling Tower asset with performance model

Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter
AS_CoolingTower.

Refer to the following procedures:

o To configure asset connection attributes.
o To map a dynamic attribute to the datasource tags.
o To set the attribute properties for the Attribute Viewer and Performance Overview.
o To manually update asset attribute information.

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 Air Preheater Monitoring

Air Preheaters is used for preheating the air which is fed to the boiler or furnace for combustion of fuels.
The primary objective of an APH is to extract the waste heat from the flue gases leaving the boiler. It also
allows control over the temperature of gases leaving the stack (to meet emissions regulations, for
example). It is installed between the economizer and chimney.

Air preheater performance monitoring plays an important role to predict the cleaning and maintenance
schedules with temperature gradient, leakage. Monitoring Basic machine health data in addition to Air
preheater operating conditions helps to maintain reliable operations of an Air preheater. There are two
areas that helps to monitor Air preheater performance to increase the availability and decrease the
energy costs.
o Process and condition monitoring
o Performance and Health monitoring

This document explains Air Preheater monitoring philosophy for process, performance, energy and
health parameters and their importance.
Item Type
Category Equipment
Equipment Class Heat Exchanger

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 Equipment Type Air Preheater

13.1 Process Performance Monitoring

The following measured parameters are monitored as they have impact on performance and health of
Air preheater, if not maintained in operating range.

Air Inlet Temperature: It is ambient air temperature going to air preheater, higher the ambient
temperature higher the outlet temperature of air preheater results in less fuel consumption.

Flue Gas Inlet Temperature: Higher the Flue gas inlet temperature to air preheater higher heat transfer
to air result in higher air outlet temperature.

Process Performance Overview: Process Performance monitoring view in UAS provides a list of the
asset attributes and their details, including the current value. This list can be used to review and update
asset attribute information, as well as to open an Asset Trend to view more details. It also highlights (in
red color) the attributes if deviates from the high or low limits.

13.2 Performance Monitoring

Performance of the Air preheater can be monitored with the help of performance indicators which
ensures the effective utilization of the equipment.

Key Performance Indicators

The following indicators help us to know overall performance of the Air preheater.

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Air Side Effectiveness
It indicates how effectively heat is transferred to Air from flue gases based on air temperature difference.
Higher effectiveness indicates more effective heat transfer.

Gas Side Effectiveness

It indicates how effectively heat is transferred from flue gases to Air based on flue gas temperature
difference. Higher effectiveness indicates more effective heat transfer.

X- Ratio (Thermal Performance)

A low X-ratio indicates excessive gas weight through the air heater or that airflow is bypassing the air
heater. A lower than design X-ratio leads to higher than design gas outlet temperature & can be used as
an indication of excessive tempering air to the mills or excessive boiler infiltration.

Leakage %
It indicates the outside air passing in flue gases, which dilutes the flue gases causing decrease in
temperature.

Performance Overview
Equipment Key Performance Indicators (KPIs) view in UAS provides a list of KPIs and their details,
including the current value. This list can be used to review and update asset attribute information, as
well as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if
deviates from the high or low limits.

13.3 Failure Modes

In Uniformance Asset Sentinel, faults, symptoms, and fault models are configured based on Air
preheater performance model outputs and process parameters measured from field to diagnose the
problems early. The fault management can inform operators of any violations of the nominal Air
preheater operating range and deviations from the expected characteristic and make this data available
for further processing through the historian. The fault symptoms or models are used to:
o Warn against potential damage to Air preheater under unfavorable operating conditions.

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 o Provide early warning of damages to the Air preheater

The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions
o Heat transfer degradation: It occurs mainly due to fouling and leakage in air preheater.
o Low effectiveness: It occurs due to variation in temperatures at inlet and outlet. It can be avoided
by operating the air preheater at optimal conditions.
o Leakage: It can be detected by checking the material balance.
o Fouling: It is an important factor in air preheater, caused due to deposition of material on the
tubes. The air preheater effective heat duty and heat transfer coefficient decreases when fouling
occurs. Fouling predictions are used to predict the maintenance schedules for cleaning heat
exchanger.
o Air outlet temperature: It determines the efficiency of other sources like furnace, boilers since
higher air outlet temperature lower heat duty required to achieve desired temperature.

Below table illustrates the list of faults and symptoms configured for an Air preheater.

Fault Category Fault Name Associated Symptoms

Tube leakage High

Air Outlet Temp Low
Air Side Effectiveness Low
Gas Side Effectiveness Low
Performance Performance Degradation Inlet Flue Gas Temp Low

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

13.4 Configuration
The purpose of the Air preheater model is to determine the operating, design, and deviation
performance. The operating performance of an Air preheater is determined using measured input data
supplied to the condition analysis program through the site instrumentation and historian. The

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operating performance is calculated for each set of measured input data. In addition to the measured
input data, a number of model parameters must also be supplied by the user through the user interface.

Model Input data

Attribute Monitoring
S No Attribute Description Units Source
Category Category

Running Operational Status of

1 Dynamic Process Field Input
Status Asset (Input)
Mean SpHeat Mean Specific Heat of Air
Thermo
2 of Air In & In & Gas Out (Required kJ/kg-C Dynamic Field Input
Properties
Gas Out Input)
SpHeat of
Specific heat of Diluted Thermo
3 Diluted Gas kJ/kg-C Dynamic Field Input
Gas Out (Required Input) Properties
Out
Gas
Temperature Gas Temperature Leaving
4 deg C Dynamic Process Field Input
Leaving (Undiluted)
(Undiluted)
Air Heater Air Inlet
Air Inlet
5 Temperature (Required deg C Dynamic Process Field Input
Temperature
Input)
Air Heater Air Exit
Air Exit
6 Temperature (Required deg C Dynamic Process Field Input
Temperature
Input)
Air Heater Gas Inlet
Gas Inlet
7 Temperature (Required deg C Dynamic Process Field Input
Temperature
Input)
Air Heater Gas Exit
Gas Exit
8 Temperature (Required deg C Dynamic Process Field Input
Temperature
Input)
Flue Gas Measured Flue Gas
weight_
9 Oxygen Oxygen Before AH Dynamic Process Field Input
percent
Before AH (Required Input)
Flue Gas Measured Flue Gas
weight_
10 Oxygen After Oxygen After AH (Required Dynamic Process Field Input
percent
AH Input)

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Model Output data
Unit Attribute Monitoring
S No Attribute Description Source
s Category Category

Air Side Air Side Effectiveness

1 % Dynamic Performance Calculated
Effectiveness (Output)
Gas Side Gas Side Efficiency
2 % Dynamic Performance Calculated
Efficiency (Output)
Gas Side Gas Side Effectiveness
3 % Dynamic Performance Calculated
Effectiveness (Output)
Air Heater
Air Heater Leakage
4 Leakage % Dynamic Performance Calculated
(Approximate)(Output)
(Approximate)
Thermal
Thermal Performance
5 Performance (X- Dynamic Performance Calculated
(X-ratio) (Output)
ratio)

Configuring an Air preheater in Uniformance Asset Sentinel

To configure an Air preheater asset with performance model

Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter
AS_AirPreheater.

Refer to the following procedures:

o To configure asset connection attributes.
o To map a dynamic attribute to the datasource tags.
o To set the attribute properties for the Attribute Viewer and Performance Overview.
o To manually update asset attribute information.

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 Centrifugal Fan Monitoring

Centrifugal fans use the kinetic energy of the impellers to increase the volume of the air stream,
which in turn moves against the resistance caused by ducts, dampers and other components.
Centrifugal fans displace air radially, changing the direction of the airflow. The main parts that is
responsible for the conversion of energy is Impeller.

Impellers: An impeller is a rotating component in a centrifugal Fan which is equipped with vanes or
blades that rotate and moves the fluid in a Fan. These vanes or blades are coupled to a shaft. When the
impeller rotates, it converts the energy derived from a source i.e. motor to induce flow of the fluid.
Impellers form an integral part of a Fan since it creates velocity to the fluid through its blades/vanes.

Bearings: A bearing is a component that helps to reduce friction on moving parts in a Fan. It supports
the shaft to rotate smoothly. Sleeve-ring oil bearings are used extensively in fans.

Fan dampers and vanes: Fan dampers are used to control gas flow into and out of the centrifugal fan.
They either installed on the inlet side or on the outlet side of the fan, or both. Dampers on the outlet side
impose a flow resistance that is used to control gas flow. Dampers on the inlet side (inlet vanes) are
designed to control gas flow by changing the amount of gas or air admitted to the fan inlet.

The centrifugal fan is one of the most widely used fans in Process Industry. They are used in transporting
gas or materials and in ventilation systems for buildings and vehicles. They are also well-suited
for industrial processes and air pollution control systems. Monitoring Basic machine health data

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in addition to fan operating conditions helps to maintain reliable fan operations. There are two areas that
helps to monitor fan performance to increase the availability and decrease the energy costs.
o Process and condition monitoring
o Performance and Health monitoring

This document explains centrifugal Fan monitoring philosophy for process, performance, energy and
health parameters and their importance.

Item Type
Category Equipment
Equipment Class Fan
Equipment Type AS_Fan

14.1 Process Performance Monitoring

The following measured parameters are monitored as it has following impact on performance and health
of the centrifugal fan, if not operated in operating range.

Suction flow rate: Increasing suction flow due to increased density at lower intake temperatures will
result in a higher free air delivery and also higher power consumption of the fan.

Suction Pressure: A decrease in suction pressure will reduce the density of the air at the fan intake. As
with higher temperatures, it will result in lower free air delivery and power. Changes in inlet pressure can
be caused by fouled inlet filters or changing barometric pressure.

Suction and Discharge temperature: The significant increase in discharge temperature over the suction
temperature indicates degradation in fan efficiency. It may occur due to improper operating conditions
or health issue of the fan.

Discharge Pressure: A lower discharge pressure indicates than the desired value indicates either high
flow or the inability of fan to fulfill the head requirement.

Process Performance Overview: Process Performance monitoring view in UAS provides a list of the
asset attributes and their details, including the current value. This list can be used to review and update
asset attribute information, as well as to open an Asset Trend to view more details. It also highlights (in
red color) the attributes if deviates from the high or low limits

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14.2 Performance Monitoring
The effective utilization of the equipment can be monitored with the help of performance indicators.

Key Performance Indicators

The following indicators help to know the overall performance of the centrifugal fan.

Operating Efficiency
Fan efficiency is defined as the ratio of actual horsepower output from the fan to the shaft horsepower
input for the fan.

Operating Efficiency = (Operating Power/ (Mechanical efficiency*Electric Power))

Operating Power
Operating power to drive fan would be lift volumetric flowrate from one elevation to another.

Operating Power (KW)= (Discharge Pressure - Suction Pressure) * Volumetric Flow Rate

Expected Efficiency
Expected efficiency is the actual design efficiency which is derived from the fan performance curve at
current volumetric flow rate.

Expected Power
Expected power is the actual design power which is derived from the pump performance curve at current
volumetric flow rate.

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Fan Load
It is ration of Actual power to Expected power.

Fan Load = 100* Actual power / Expected power

Performance Overview
Equipment Key Performance Indicators (KPIs) view in UAS provides a list of KPIs and their details,
including the current value. This list can be used to review and update asset attribute information, as
well as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if
deviates from the high or low limits.

14.3 Failure Modes

In Uniformance Asset Sentinel, you can configure faults, symptoms, and fault models on Fan
performance output to diagnose the problems early. The fault management can inform operators of any
violations of the nominal fan operating range and deviations from the expected characteristic and make
this data available for further processing through the historian. The fault symptoms or models are used
to:
o Warn against potential damage to fan under unfavorable operating conditions.
o Provide early warning of damages to the fan.

The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions
o Low fan efficiency: It is determined by means of the deviation of the current fan efficiency from the
efficiency characteristic.
o High solid content: It is determined by means of the reduction in delivery height or head.
o Blockage: It is determined on the basis of a limit value for an electrical power being undershot.
o Dry running: It is determined on the basis of a (second, lower) limit value for an electrical power
being undershot.
o Incorrect direction of rotation (the motor was connected incorrectly and rotates in the wrong
direction): It is determined when the delivery head falls significantly (> 40%) but with only a slight
deviation (< 20%) of the power characteristic.
o Limit value violation for power values (e.g. electrical overload).

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 o Deviation of the operating point from the flow characteristic (i.e. reduction in delivery height or
head: indication of high gas content, blockage, or dry running). This is configured by flow loss or
capacity loss of fan.
o Deviation of the operating point from the power characteristic: It is configured by percent
deviation in power between operating and design values.

Fault Category Fault Name Associated Symptoms

Efficiency Low
Load High
Performance Performance Degrafation
Load Low
Efficiency Deviation Hight
Health Health Degradation Fan Noise Level High

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

14.4 Configuration
As described in previous sections, centrifugal fan performance monitoring model is used to:
o Calculate the current operating point data such as head, power consumed,etc. The calculation is
performed based on the inputs received from DCS/Historian or based on the configured model
parameters.
o Interpolate or extrapolate the design data for the current operating FlowRate from the
Manufacturer performance curve.

The calculation model to perform as expected, it requires some inputs are to be feed into the model. The
centrifugal fan model input data consists of measured data and static data. Measured input data is
supplied to the model from DCS or Historian by tag mapping. This section describes the list of input and
output attributes and its properties.

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Model Input data
Attribute Monitoring
Sr No Attribute Description Unit Source
Category Category

Running Operational Status of

1 Status Asset (Input) Dynamic Process Field Input
Fan Driver Fan Driver
2 power power(Input) Dynamic kW Process Field Input
Current (Required
Input if Electrical
3 Current Power is not given) Dynamic Amperes Process Field Input
Measured Speed
4 Speed (Input) Dynamic rpm Process Field Input
Suction Suction Pressure
5 Pressure (Required Input) Dynamic barg Process Field Input
Discharge Discharge
6 Pressure Pressure(Input) Dynamic barg Process Field Input
Volume Flow Rate
7 FlowRate (Required Input) Dynamic m3/hr Process Field Input
Suction Suction Temperature
8 Temperature (Required Input) Dynamic deg C Process Field Input
Radial Bearing Radial Bearing 1 millimetres
9 1 Vibration X Vibration X(Input) Dynamic /second Process Field Input
Radial Bearing Radial Bearing 1 millimetres
10 1 Vibration Y Vibration Y(Input) Dynamic /second Process Field Input
Radial Bearing Radial Bearing 2 millimetres
11 2 Vibration X Vibration X(Input) Dynamic /second Process Field Input
Radial Bearing Radial Bearing 2 millimetres
12 2 Vibration Y Vibration Y(Input) Dynamic /second Process Field Input
Efficiency Efficiency
Performance Performance ct. A0
13 ct. A0 (Required Input) Dynamic Design Constant
Efficiency Efficiency
Performance Performance ct. A1
14 ct. A1 (Required Input) Dynamic Design Constant
Efficiency Efficiency
Performance Performance ct. A10
15 ct. A10 (Required Input) Dynamic Design Constant
Efficiency Efficiency
Performance Performance ct. A11
16 ct. A11 (Required Input) Dynamic Design Constant
Efficiency Efficiency
Performance Performance ct. A2
17 ct. A2 (Required Input) Dynamic Design Constant
18 Efficiency Efficiency Dynamic Design Constant

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 Attribute Monitoring
Sr No Attribute Description Unit Source
Category Category
Performance Performance ct. A3
ct. A3 (Required Input)
Efficiency Efficiency
Performance Performance ct. A4
19 ct. A4 (Required Input) Dynamic Design Constant
Efficiency Efficiency
Performance Performance ct. A5
20 ct. A5 (Required Input) Dynamic Design Constant
Efficiency Efficiency
Performance Performance ct. A6
21 ct. A6 (Required Input) Dynamic Design Constant
Efficiency Efficiency
Performance Performance ct. A7
22 ct. A7 (Required Input) Dynamic Design Constant
Efficiency Efficiency
Performance Performance ct. A8
23 ct. A8 (Required Input) Dynamic Design Constant
Efficiency Efficiency
Performance Performance ct. A9
24 ct. A9 (Required Input) Dynamic Design Constant
Blade Natural
Blade Natural Frequency (Required
25 Frequency Input) Dynamic Design Constant
Blade Pitch
Angle Blade Pitch Angle
26 (Reference) (Reference) Dynamic Design Constant
Blade Blade Clearence
27 Clearence (Required Input) Dynamic Design Constant
Rotor Diameter
28 Rotor Diameter (Required Input) Dynamic Design Constant
Driver Rated Driver Rated Power
29 Power [optional] Dynamic kW Design Constant
MechEfficienc Mechanical Efficiency
30 y (Required Input) Dynamic % Design Constant
Gear Ratio (Required
31 Gear Ratio Input) Dynamic Design Constant
Motor Power Motor Power Factor
32 Factor [optional] Dynamic Design Constant
Voltage (Required
Input if Electrical
33 Voltage Power is not given) Dynamic V Design Constant
Number of Number of Blades
34 Blades (Required Input) Dynamic Design Constant
35 Number of Number of Obstacles Dynamic Design Constant

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 Attribute Monitoring
Sr No Attribute Description Unit Source
Category Category
Obstacles (Required Input)
Rated Fan Speed
36 Rated Speed (Required Input) Dynamic rpm Design Constant
Rated Power (Required
37 Rated Power Input) Dynamic kW Design Constant
Rated Fan Static
Rated Fan Pressure (Required
38 Static Pressure Input) Dynamic Design Constant
Noise Level Noise Level
Calculation Calculation Type
39 Type (Required Input) Dynamic Design Constant
Blade
Rotational Blade Rotational
Displacement Displacement Volume
40 Volume (Required Input) Dynamic Design Constant
Fan Blade Fan Blade Control
Control Pich Pich Angle (Required
41 Angle Input) Dynamic Design Constant
Fan Inlet Guide Fan Inlet Guide Vane
42 Vane Angle Angle(Required Input) Dynamic % Design Constant

Model Output data

Sr Attribute Monitoring
Attribute Description Unit Source
No Category Category

Operating Fan Actual

1 Efficiency Efficiency(Output) Dynamic % Performance Calculated
Operating Actual Fan
2 Power Power(Output) Dynamic kW Performance Calculated
Expected Expected Fan
3 Power Power(Output) Dynamic kW Performance Calculated
Expected Fan Expected
4 Efficiency Efficiency(Output) Dynamic % Performance Calculated
5 Fan Load Fan Load(Output) Dynamic % Performance Calculated
Sound Power Sound Power
6 Level Level(Output) Dynamic decibel Performance Calculated

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Configuring a Centrifugal Fan in Uniformance Asset Sentinel
To configure a centrifugal fan asset with performance model

Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter AS_Fan.

Refer to the following procedures:

o To configure asset connection attributes.
o To map a dynamic attribute to the datasource tags.
o To set the attribute properties for the Attribute Viewer and Performance Overview.
o To manually update asset attribute information.

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 Diesel Generator Monitoring

A Generator is a device that converts mechanical energy obtained from an external source into electrical
energy as the output. Generator uses the mechanical energy supplied to it to force the movement of
electric charges present in the wire of its windings through an external electric circuit. This flow of
electric charges constitutes the output electric current supplied by the generator. The main components
of a generator as below.

Engine: The engine is the source of the input mechanical energy to the generator. The size of the engine
is directly proportional to the maximum power output the generator can supply.

The Alternator: This is the part which turns the mechanical energy (the rotation of the shaft) into
electrical power through induction. When a diesel engine turns the central shaft, the rotor constantly
moves the north and south poles of its magnetic fields across the bundles of wire that surround them.
This causes a great deal of electrical current to flow back and forth through the wires.

The Fuel System: This is typically the diesel fuel supply for the engine. This tank may be inside the
generator housing for smaller, or portable units, or it may be a separate external structure for larger,
permanently installed units.

The Voltage Regulator: It regulates the AC current provided according to the speed of the engine.

The Cooling System: As the generator produces a great deal of waste heat in addition to mechanical
energy. This heat should be soaked up by a cooling system.

The Lubrication (oil) System: Any engine requires lubrication, and this is handled by an oil pump and
reservoir attached to the engine itself.

There are two areas that helps to monitor Diesel Generator performance to increase the availability and
decrease the energy costs.
o Process and condition monitoring
o Performance and Health monitoring

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This document explains diesel generator monitoring philosophy for process, performance, energy and
health parameters and their importance.
Item Type
Category Equipment
Equipment Class Engine
Equipment Type Engine Diesel

15.1 Process Performance Monitoring

The following measured parameters are monitored as they have impact on performance and health of
diesel generator, if not maintained in operating range.

Measured Voltage (V): When a motor is operated at reduced voltage, even within the allowable 10%
limit, the motor will draw increased current to produce the torque requirements imposed by the load.
This causes an increase in both stator and rotor resistance losses with subsequent increased heating at
rated horsepower load or service factor operation. Operating a motor at the outer limits of its voltage
requirements reduces its efficiency and causes premature failure. Whereas increase in voltage,
magnetizing current increases by an exponential function. Depending upon design of the motor,
saturation of the core iron will occur, and overheating will result. At about 10% to 15% above the motor’s
design voltage (overvoltage), both efficiency and power factor significantly decrease for standard
efficiency motors, while the full-load slip decreases.

Measured Current (Amps): An increase in current is a danger to the motor only if that current
exceeds the motor's nameplate current rating. When amps go above the nameplate rating, heat begins
to build up in the motor. The more heat and the longer the exposure to it, the more damage to the motor.
Whereas decreasing in current than require result in decrease efficiency of equipment.

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Measured Power (KW): To drive a fixed mechanical load connected to the shaft, a motor must draw a
fixed amount of power from the line. Power is directly impact rotational speed and torque. As more load
is applied the motor draws more current, which increases torque. However, as power increase the
speed of motor increase. Fluctuation in power impact efficiency and operation of equipment.

Process Performance Overview: Process Performance monitoring view in UAS provides a list of the
asset attributes and their details, including the current value. This list can be used to review and update
asset attribute information, as well as to open an Asset Trend to view more details. It also highlights (in
red color) the attributes if deviates from the high or low limits.

15.2 Performance Monitoring

Key Performance Indicators
The following indicators help us to know overall performance of the diesel generator.

Motor Efficiency
Motor Efficiency of diesel generator is calculated as “Percentage of Actual Power Output / Actual Power
Input”.

Motor efficiency = (Actual Power Output / Actual Power Input) *100

Higher the efficiency, better the motor. For ideal motor, the efficiency is 100%. However, efficiency
cannot be more than 100%.

Actual Power Input is calculated as,

Pi = (V x I x PF x √3)/1000

Where:

Pi = Three-phase power in kW

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V = RMS voltage, mean line-to-line of 3 phases

I = RMS current, mean of 3 phases

PF = Power factor as a decimal

Actual power output = Shaft power of equipment (Power transmitted by motor to shaft)

Expected Efficiency
Expected Efficiency of DC motors is calculated using following empirical equation

Expected efficiency = A*ML^2 + B*ML + ML

Where,

ML= Motor Load

A = -0.00125

B=0.175

Motor Load
This is the ratio of Actual Input Power to Rated Power (Nameplate Power).

Actual Input Power is calculated as,

Pi = (V x I x PF x √3)/ 1000

Where:

Pi = Three-phase power in kW

V = RMS voltage, mean line-to-line of 3 phases

I = RMS current, mean of 3 phases

PF = Power factor as a decimal

Rated power is calculated as,

Pir = (hp x 0.7457)/ηfl

Where:

Pir = Input power at full-rated load in kW

hp = Nameplate rated horsepower

ηfl = Efficiency at full-rated load

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Electric motor datasheet usually provides the efficiency and power factor at full load and at various part
loads (for example 50%,75%).

Performance Overview
Equipment Key Performance Indicators (KPIs) view in UAS provides a list of KPIs and their details,
including the current value. This list can be used to review and update asset attribute information, as
well as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if
deviates from the high or low limits.

15.3 Failure Modes

In UAS, a fault model is built to identify possible anomalies that affects the performance or health of a
Diesel Generator. The fault management can inform operators of any violations of the nominal diesel
generator operating range and deviations from the expected characteristic and make this data available
for further processing through the historian.

The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions
o Low Efficiency: Occurs mainly due to improper load conditions. At low load, the frictional losses
cause low efficiency of the motor. At high load, as the load torque increases the speed of the motor
decreases which will impact the motor efficiency. Hence, it is required to optimize the load on motor
to achieve maximum efficiency.
o Overheating: Occurs due to excessive load on motor which will cause damage to the motor. It is
important to monitor the housing and winding temperatures to maintain the health of the motor.

Below table illustrates the list of faults and symptoms configured for a Diesel Generator.

Fault Category Fault Name Associated Symptoms

Load High
Performance
Performance Load Low
Degradation
Efficiency Low
Health Health Degradation Temperature High

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The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

15.4 Configuration
The calculation model to perform as expected, it requires some inputs are to be feed into the model. The
Diesel Generator model input data consists of measured data and static data. Measured input data is
supplied to the model from DCS or Historian by tag mapping. This section describes the list of input and
output attributes and its properties.

Model Input data

S Attribute Monitoring
Attribute Description Units Source
No Category Category

Constant A
Constant A (Expected Constant From
(Expected efficiency) Manufacturer
1 efficiency) (Input) Static Design Data Sheet
Constant B
Constant B (Expected Constant From
(Expected Efficiency) Manufacturer
2 Efficiency) (Input) Static Design Data Sheet
Constant C
Constant C (Expected Constant From
(Expected Efficiency) Manufacturer
3 Efficiency) (Input) Static Design Data Sheet
Rated Power
4 Rated Power (Input) Static Design Constant
Active Power
5 Active Power (Input) kW Dynamic Process Constant
Fuel Heating Fuel Heating
6 Value Value (Input) Dynamic Process Constant
Fuel Mass Fuel Mass Flow
7 Flow (Input) kg/hr Dynamic Process Constant

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 S Attribute Monitoring
Attribute Description Units Source
No Category Category

8 Current Current (Input) Amperes Dynamic Process Constant

Power Factor
9 Power Factor (Input) Dynamic Process Constant
Housing
Housing Temperature
10 Temperature (Input) deg C Dynamic Process Constant
11 Voltage Voltage (Input) V Dynamic Process Constant
Running
12 Status Running Status Dynamic Process Constant

Model Output data

S Attribute Monitoring
Attribute Description Units Source
No Category Category

Operating
Operating Efficiency
1 Efficiency (Output) % Double Performance Calculated

Operating Operating Power

2 Power (Output) kW Double Performance Calculated

Fuel Power
3 Fuel Power (Output) kW Double Performance Calculated

Expected
Expected Efficiency
4 Efficiency (Output) % Double Performance Calculated

Generator Generator Load

5 Load (Output) % Double Performance Calculated

Configuring a Diesel Generator in Uniformance Asset

Sentinel
To configure a Two-Phase Valve asset with performance model

Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter
As_Engine_Diesel.

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Refer to the following procedures:
o To configure asset connection attributes.
o To map a dynamic attribute to the datasource tags.
o To set the attribute properties for the Attribute Viewer and Performance Overview.
o To manually update asset attribute information.

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 Electrical Submersible Pump
Monitoring

Electrical submersible pumps are used to pump liquid in process industries. An electric motor drives the
pump to increase the fluid’s kinetic energy which converts into pressure. This pressure lifts the fluid
through the pump. ESPs are basically centrifugal pumps with vertical shafts. The main advantage of this
type of pump is that it prevents pump cavitation, a problem associated with a high elevation difference
between pump and the fluid surface.

This document explains ESP monitoring philosophy for process, performance, energy and health
parameters and their importance.

Monitoring Basic machine health data in addition to ESP operating conditions helps to maintain reliable
ESP operations. There are three areas that helps to monitor ESP performance to increase the availability
and decrease the energy costs.
o Process and condition monitoring
o Energy monitoring
o Performance and Health monitoring

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 Item Type
Category Equipment
Equipment Class Pump
Equipment Type Electrical Submersible Pump

16.1 Process Performance Monitoring

The following measured parameters are monitored as it has following impact on performance and health
of the ESP, if not operated in operating range.

Reservoir Pressure: Reservoir pressure is important factors that control the deliverability of gas
wells and the only one that decreases continuously with production going on; in fact, the decline
of reservoir pressure dominates the reduction of deliverability. Reservoir pressure is a basic control on
gas capacity and reservoir behavior and consists of two principal components, one is lithostatic pressure
and other one is hydrostatic pressure.

Wellhead Pressure: Wellhead pressure helps to control fluid flow. When wellhead pressure low the
reservoir is able to produce more fluids at same drawdown.

Pump suction Temp: The ESP suction temperature used in the design is based primarily on the dynamic
well temperature and the effect of produced fluid flowing between the ESP unit and the casing. Suction
temperature exceeding the ESP's design rating can reduce the expected life.

Producing Gas Oil Ratio: Presence of free gas at pump intake affects the pump performance negatively,
reducing the liquid rates and the pressure added by the pump. This performance reduction resulting in
unstable pump operation, significant production losses, lower reliability and increased operating costs
due to premature equipment failure. If the bore fluid contains a relatively high oil-gas ratio, If the gas-oil
ratio is low the gas separator is not required at the pump inlet.

Process Performance Overview: Process Performance monitoring view in UAS provides a list of the
asset attributes and their details, including the current value. This list can be used to review and update
asset attribute information, as well as to open an Asset Trend to view more details. It also highlights (in
red color) the attributes if deviates from the high or low limits.

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16.2 Performance Monitoring
The effective utilization of the equipment can be monitored with the help of performance indicators.

Key Performance Indicators

The following indicators help to know the overall performance of the ESP

% free gas to total volume of fluid at inlet

It is ratio of volume of gas at pump inlet to total capacity of pump intake.

free gas to total volume of fluid at inlet= (Volume of gas at the pump intake / Total fluid volume at the
pump intake) *100

Total number of stages required

It is ratio of total dynamic head required by pump to head given by one stage.

Total number of stages required= Total Dynamic Head / (Head/Stage)

Productivity Index
The productivity index (PI) is equal to the liquid flow rate divided by the well drawdown (Pr-Pwf).

Productivity Index=Production Rate /(Reservoir Pressure -Flowing bottom hole pressure)

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Pump Power required
It is power per stage to total no of stages required.

Pump Power required: Power Per Stage * Total number of stages required *Specific
Gravity of Fluid

Total Dynamic Head(ft)

It is net head of electrical submersible pump.

Total Dynamic Head= Net Well Lift+ Tubing Friction Loss + Wellhead Pressure Head

Performance Overview
Equipment Key Performance Indicators (KPIs) view in UAS provides a list of KPIs and their details,
including the current value. This list can be used to review and update asset attribute information, as
well as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if
deviates from the high or low limits.

16.3 Failure Modes

In Uniformance Asset Sentinel, you can configure faults, symptoms, and fault models on ESP
performance output to diagnose the problems early. The fault management can inform operators of any
violations of the nominal ESP operating range and deviations from the expected characteristic and
make this data available for further processing through the historian. The fault symptoms or models are
used to:
o Warn against potential damage to ESP under unfavorable operating conditions.
o Provide early warning of damages to the ESP.

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The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions
o Low pump efficiency: It is determined by means of the deviation of the current pump efficiency
from the efficiency characteristic.
o High gas content: It is determined by means of the reduction in delivery height or head.
o Blockage: It is determined on the basis of a limit value for an electrical power being undershot.
o Incorrect direction of rotation (the motor was connected incorrectly and rotates in the wrong
direction): It is determined when the delivery height or head falls significantly (> 40%) but with only a
slight deviation (< 20%) of the power characteristic.
Limit value violation for power values (e.g. electrical overload).
o Deviation of the operating point from the flow characteristic (i.e. reduction in delivery height or
head: indication of high gas content, cavitation, blockage, or dry running). This is configured by flow
loss or capacity loss of pump.
o Deviation of the operating point from the power characteristic: It is configured by percent
deviation in power between operating and design values.

Below table illustrates the list of faults and symptoms configured for a pump to identify possible
anomalies that affects the performance or health of a pump.

Fault Associated
Category Fault Name Symptoms

High Power
Consumption
Low Productivity
Performance Low ESP Performance Index
Health ESP Health Degradation High Suction Temp

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

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16.4 Configuration
As described in previous sections, ESP performance monitoring model is used to:

o Calculate the current operating point data such as head, power consumed. The calculation is
performed based on the inputs received from DCS/Historian or based on the configured model
parameters.
o Interpolate or extrapolate the design data for the current operating FlowRate from the
Manufacturer performance curve.

The calculation model to perform as expected, it requires some inputs are to be feed into the model. The
ESP model input data consists of measured data and static data. Measured input data is supplied to the
model from DCS or Historian by tag mapping. This section describes the list of input and output
attributes and its properties.

Model Input data

Attribute Monitoring
Sr No Attribute Description Unit Source
Category Category

Correction Correction Factor

1 Factor (Input) Dynamic Design Constant
Specific
gravity of Specific gravity of
2 gas gas (Input) Dynamic Design Constant
Inlet Tube Inlet Tube Diameter
3 Diameter (Input) inch Dynamic Design Constant
Oil gravity
4 API oil gravity API (Input) API_gravity Dynamic Design Constant
Pump Intake Pump Intake Depth
5 Depth (Input) m Dynamic Design Constant
Specific
gravity of Specific gravity of
6 Water Water (Input) Dynamic Design Constant
Top Top Perforation
7 Perforation (Input) m Dynamic Design Constant
8 Z factor Z factor (Input) Dynamic Design Constant
Producing Producing Gas Oil
9 Gas Oil Ratio Ratio (Input) Dynamic Process Field Input
Head/Stage
10 Head/Stage (Required Input) foot Dynamic Process Field Input
Pump inlet Pump inlet pressure
11 pressure (Required Input) psig Dynamic Process Field Input
Pump Depth
12 Pump Depth (Required Input) foot Dynamic Process Field Input
13 Power Per Power Per Stage horsepower Dynamic Process Field Input

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 Attribute Monitoring
Sr No Attribute Description Unit Source
Category Category
Stage (Required Input)

Reservoir Reservoir Pressure

14 Pressure (Required Input) psig Dynamic Process Field Input
Production Production Rate
15 Rate (Required Input) barrel/day Dynamic Process Field Input
Suction Suction Temp
16 Temperature (Required Input) F Dynamic Process Field Input
Water Cut (Required
17 Water Cut Input) % Dynamic Process Field Input
Wellhead Wellhead Pressure
18 Pressure (Input) psig Dynamic Process Field Input
Performance
19 Data Performance Data Static Design Constant
Running
20 Status Running Status Dynamic Process Field Input

Model Output data

Sr Attribute Monitoring
Attribute Description Unit Source
No Category Category

% free gas to % free gas to total

total volume of volume fluid at
1 fluid at inlet inlet(Output) % Dynamic Performance Calculated
Total number Total number of
of stages stages
2 required required(Output) Dynamic Performance Calculated
Productivity Productivity barrel_per_
3 Index Index(Output) day_per_psi Dynamic Performance Calculated
Pump Power Pump Power
4 required required(Output) horsepower Dynamic Performance Calculated
Flowing Flowing bottom
bottom hole hole
5 pressure pressure(Output) psig Dynamic Performance Calculated
Solution gas- Solution gas-oil
6 oil ratio ratio(Output) Dynamic Performance Calculated
Total Dynamic Total Dynamic
7 Head Head(Output) foot Dynamic Performance Calculated
Total Mass of Total Mass of
Produced Produced pound_mas
8 Fluid Fluid(Output) s_per_day Dynamic Performance Calculated

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Configuring an Electrical Submersible Pump in Uniformance
Asset Sentinel
To configure an Electrical Submersible Pump asset with performance model

Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter
As_Engine_Diesel.

Refer to the following procedures:

o To configure asset connection attributes.
o To map a dynamic attribute to the datasource tags.
o To set the attribute properties for the Attribute Viewer and Performance Overview.
o To manually update asset attribute information.

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 Fired Heater Monitoring

Fired heater heats the process fluid to high temperature from the heat generated by the combustion of
fuel. An industrial fired heater comprises below segments:

Radiant section: In this section of a heater, the portion of heat is transferred to the tubes by
radiation from the flame. The Tubes can be vertical or horizontal which are placed in a distance away
from the insulation so radiation can be reflected to the back of the tubes to maintain a uniform tube wall
temperature.

Convection section: In this portion of a heater, the portion of heat is transferred to the tubes by
radiation from the flame. Heat transfer takes place by convection here, and the tubes are finned
to increase heat transfer.

Burner: Introduces fuel and air into a heater at the desired velocities and concentration to establish and
maintain proper ignition and combustion.

Stack: The flue gas stack is a cylindrical structure at the top of all the heat transfer chambers, which
is used to discharge flue gas to the atmosphere

Monitoring Basic machine health data in addition to fired heater operating conditions helps to maintain
reliable fired heater operations. There are three areas that helps to monitor fired heater performance to
increase the availability and decrease the energy costs.

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 o Process and condition monitoring
o Energy monitoring
o Performance and Health monitoring

This document explains fired heater monitoring philosophy for process, performance, energy and health
parameters and their importance.

Item Type
Category Equipment
Equipment Class Heaters
Equipment Type Fired Heater

17.1 Process Performance Monitoring

The following measured parameters are monitored as it has following impact on performance and health
of the fired heater if not operated in operating range.

Air Outlet Temperature: It depends upon the flue gas inlet temperature to air preheater, higher the flue
gas temperature increases inlet temperature of air to fired heater which helps in thermal efficiency of
fired heater.

Flue Gas Temp/ Stack Temp: This indicates exit gas/stack gas temperature of the fired heater. More the
temperature indicates in-efficient use of combustion energy.

Fuel gas composition: The change of the composition of hydrocarbons and inert gases like CO2 and N2
influences the ignitability and the combustion behavior of the fuel gas mixture. The lower quality fuels
results in poor combustion, misfire or engine knocking. Changing combustion parameters influence the
exhaust emissions, the cylinder peak pressure and the knock margin. High frequency fluctuations have
an impact on the fired heater load controller and can result in unstable operation and varying emissions
levels.

Draft pressure: Optimum operation requires that excess air in the flue gas entering the convection
section be minimized and there should be a very small negative pressure at the convection section inlet.
Excessive draft, either positive pressure or negative pressure, can lead to severe problems.

NOX Emission: Stringent emission limits require greater control of NOx and other stack components.
Operating the heater at optimum efficiency, with low excess air firing is the simplest and least expensive
way to reduce NOx emissions. The high temperature in the flame and radiant section, together with
combustion turbulence at the burners, causes reaction of oxygen with nitrogen forming NO (nitric oxide)
and NO2 (nitrogen dioxide). Low excess air firing (LEA) is the simplest way to reduce NOx formation and
improve efficiency. The more excess air, the more oxygen is available to produce NOx. Low NOx burners
stage the combustion reducing the available oxygen, temperature or residence time to limit the
formation of NOx.

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CO Emission: This indicates current CO ppm levels in the exit gases of the fired heater. More the level
indicates incomplete combustion of fuel and lower efficiency of the fired heater. More CO levels adds
risk for plant and environment safety as well.

Stack O2 %: This indicates Air or O2 percent in the exit gases of the fired heater. More O2 indicates that
the fired heater is operating at more AF (air to fuel) ratio. More O2 content than desired indicates losses
to preheat excess air supply to combustion temperature. Less O2 indicates that the fire heater is
operating at lower AF (air to fuel) ratio. This can cause incomplete combustion of fuel and reduce
thermal efficiency of the fired heater.

Process Performance Overview:

Process Performance monitoring view in UAS provides a list of the asset attributes and their details,
including the current value. This list can be used to review and update asset attribute information, as
well as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if
deviates from the high or low limits.

17.2 Energy Monitoring

Energy Monitoring explains the KPIs to be monitored to optimize the energy consumption by fired
heater.

Heat Losses: This indicates the total heat losses in furnace

Heat Losses = Stack Heat Loss + Radiation Loss

17.3 Performance Monitoring

The effective utilization of the equipment can be monitored with the help of performance indicators.

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Key Performance Indicators
The following indicators help to know the overall performance of the Fired Heater

Furnace Efficiency
The efficiency of a furnace is the ratio of useful output to heat input. The furnace efficiency can be
determined by both direct and indirect method.

Excess Air
For fired heater safety and maintenance needs, additional air beyond the theoretical “air to fuel ratio”
needs to be added this is called as “excess air.” With fired heater combustion, if some excess air is not
added to the combustion process, unburned fuel, soot, smoke, and carbon monoxide exhaust will create
additional emissions and surface fouling.

Air to fuel ratio

The ratio of air to fuel is the most efficient for combustion in fired heater, the quantity of fuel and air
would be in a perfect ratio to provide perfect combustion with no unused fuel or air.

Convection section heat transfer efficiency

The convection section heat transfer efficiency calculated using terminal temperature difference.

Radiation section heat transfer efficiency

The radiation section heat transfer efficiency calculated using terminal temperature difference.

Shutdown Revenue loss

Shutdown revenue loss is calculated based on Fuel Compensation for Furnace duty loss in various
section multiplied by the unit rate of fired fuel.

Maintenance revenue loss

Maintenance revenue loss is calculated based on revenue loosed for cleaning assets.

Performance Overview
Equipment Key Performance Indicators (KPIs) view in UAS provides a list of KPIs and their details,
including the current value. This list can be used to review and update asset attribute information, as
well as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if
deviates from the high or low limits.

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17.4 Failure Modes
In UAS, a fault model is built to identify possible anomalies that affects the performance or health of a
Fired Heater. The fault management can inform operators of any violations of the nominal fired heater
operating range and deviations from the expected characteristic and make this data available for further
processing through the historian. The fault symptoms or models are used to:
o Warn against potential damage to fired heater under unfavorable operating conditions.
o Provide early warning of damages to the fired heater.

The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions
o Low fired heater efficiency: It is determined by means of the deviation of the current fired heater
efficiency from the design efficiency.
o Incomplete combustion: It indicate fuel is not completely utilized to generate heat in form of
energy. It can be determining by stack C0, NOX and O2 concentration.
o Backfire: It indicate pressure inside fired heater is higher which resist burning of fuel. This can be
happed due to high draft pressure and low stack damper opening.
o Hotspot on tubes: This determines by high skin temperature and can damage tubes of fired
heater.

Below table illustrates the list of faults and symptoms configured for a fired heater.
Fault
Fault Name Associated Symptoms
Category
Fired Heater Efficiency Low
Radiation Section Efficiency Low
Performance Performance Degradation
Convection Section Efficiency Low
Radiation Section Fouling High

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 Fault
Fault Name Associated Symptoms
Category
Convection Section Fouling High
Oxygen Level High
High Fuel Gas to Product Ratio
Health Health Degradation Flame impingement
HotSpot Warning
Furnace Internal Pressure High
Health Backfire Warning
Stack Damper Closed
Flue Gas NOX Level High
Energy Cyclic Combustion
Flame Detection failure
Combustion Air Low
Performance Incomplete Combustion O2 in Flue Gas Low
CO in Flue Gas High

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation views.

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17.5 Configuration
As described in previous sections, fired heater performance monitoring model is used to:
o Calculate the current operating point data such as heat loss, load and efficiency. The calculation is
performed based on the inputs received from DCS/Historian or based on the configured model
parameters.

The calculation model to perform as expected, it requires some inputs are to be feed into the model. The
fired heater model input data consists of measured data and static data. Measured input data is
supplied to the model from DCS or Historian by tag mapping. This section describes the list of input and
output attributes and its properties.

Model Input data

S Attribute Monitoring
Attribute Description Units Source
no Category Category

Running Running Status of

1 Dynamic Process Field Input
Status Asset (Input)
APH Flue Air Preheater Section
2 Gas Flue Gas barg Dynamic Process Field Input
Pressure Pressure(Input)
APH Flue Air Preheater Section
3 Gas Inlet Flue Gas Inlet deg C Dynamic Process Field Input
Temp. Temp(Input)
APH Flue Air Preheater Section
4 Gas Outlet Flue Gas Outlet deg C Dynamic Process Field Input
Temp. Temp(Input)
Air through Air
Air through
5 Preheater m3/hr Dynamic Process Field Input
APH Flow
Flow(Input)
APH Tube
Air Preheater Tube
6 Inlet barg Dynamic Process Field Input
Inlet Pressure(Input)
Pressure
APH Tube Air Preheater Tube
7 Outlet Outlet barg Dynamic Process Field Input
Pressure Pressure(Input)
APH Tube Air Preheater Tube
8 deg C Dynamic Process Field Input
Inlet Temp Inlet Temp(Input)
APH Tube Air Preheater Tube
9 deg C Dynamic Process Field Input
Outlet Temp Outlet Temp(Input)
Air through
Air through Air
APH Flow
Preheater Flow
10 Diverter Dynamic Process Field Input
Diverter Valve
Valve
Opening(Input)
Opening

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 S Attribute Monitoring
Attribute Description Units Source
no Category Category

%Volume Air
11 Air N2 % Dynamic Process Field Input
N2(Input)
%Volume Air
12 Air O2 % Dynamic Process Field Input
O2(Input)
Cost of HEX Cost of HEX
13 Cleaning Cleaning $ Dynamic Process Field Input
Operation Operation(Input)
Duration of
Duration of Cleaning
14 Cleaning hour Dynamic Process Field Input
Operation(Input)
Operation
Combustion Combustion Air
15 m3/hr Dynamic Process Field Input
Air Flow Flow(Input)
Combustion
Combustion Air
16 Air deg C Dynamic Process Field Input
Temperature(Input)
Temperature
Convection Section
CS Flue Gas
17 Flue Gas barg Dynamic Process Field Input
Pressure
Pressure(Input)
CS Inlet Convection Section
18 deg C Dynamic Process Field Input
Temp. Inlet Temp.(Input)
CS Outlet Convection Section
19 deg C Dynamic Process Field Input
Temp. Outlet Temp.(Input)
CS Tube Convection Tube
20 m3/hr Dynamic Process Field Input
Stream Flow Stream Flow(Input)
CS Tube
Convection Tube
21 Inlet barg Dynamic Process Field Input
Inlet Pressure(Input)
Pressure
CS Tube Convection Tube
22 Outlet Outlet barg Dynamic Process Field Input
Pressure Pressure(Input)
CS Tube Convection Tube
23 deg C Dynamic Process Field Input
Inlet Temp Inlet Temp(Input)
CS Tube Convection Tube
24 deg C Dynamic Process Field Input
Outlet Temp Outlet Temp(Input)
Flue Gas
Flue Gas OUT
25 OUT % Dynamic Process Field Input
Analysis CO(Input)
Analysis CO
Flue Gas
OUT Flue Gas OUT
26 % Dynamic Process Field Input
Analysis Analysis CO2(Input)
CO2
Flue Gas Flue Gas OUT
27 % Dynamic Process Field Input
OUT Analysis N2

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 S Attribute Monitoring
Attribute Description Units Source
no Category Category

Analysis N2 (atm)(Input)
(atm)
Flue Gas
OUT Flue Gas OUT
28 % Dynamic Process Field Input
Analysis Analysis NOX(Input)
NOX
Flue Gas
Flue Gas OUT
29 OUT % Dynamic Process Field Input
Analysis O2(Input)
Analysis O2
Gas Fuel
Gas Fuel Heating
Heating
30 Value (LHV or kJ/kg Dynamic Process Field Input
Value (LHV
HHV)(Input)
or HHV)
Gas Fuel
31 Gas Fuel Flow(Input) m3/hr Dynamic Process Field Input
Flow
32 Cost of Fuel Cost of Fuel(Input) Dynamic Process Field Input
Fuel Higher
Fuel Higher Heating
33 Heating MJ/kg Dynamic Process Field Input
Value(Input)
Value
Draft Furnace Pressure inches_
34 Dynamic Process Field Input
Pressure (Input) H2O
Radiation Section
RS Flue Gas
35 Flue Gas barg Dynamic Process Field Input
Pressure
Pressure(Input)
Radiation Section
RS Flue Gas
36 Flue Gas Inlet deg C Dynamic Process Field Input
Inlet Temp
Temp(Input)
Radiation Section
RS Flue Gas
37 Flue Gas Outlet deg C Dynamic Process Field Input
Outlet Temp
Temp(Input)
RS Tube Radiation Tube
38 Dynamic Process Field Input
Stream Flow Stream Flow(Input)
RS Tube
Radiation Tube Inlet
39 Inlet barg Dynamic Process Field Input
Pressure(Input)
Pressure
RS Tube Radiation Tube
40 Outlet Outlet barg Dynamic Process Field Input
Pressure Pressure(Input)
RS Tube Radiation Tube Inlet
41 deg C Dynamic Process Field Input
Inlet Temp. Temp.(Input)
RS Tube Radiation Tube
42 deg C Dynamic Process Field Input
Outlet Temp. Outlet Temp.(Input)
43 Stack Stack Dampner % Dynamic Process Field Input

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 S Attribute Monitoring
Attribute Description Units Source
no Category Category

Dampner Opening(Input)
Opening
Furnace
Skin Furnace Skin
44 deg C Dynamic Process Field Input
Temperature Temperatures(Input)
s
Constant
APH Tube Air Preheater Tube from
45 m2 Dynamic Design
Area Area (Input) Manufacture
r datasheet
Constant
APH Tube Air Preheater Tube
from
46 Product Product Density kg/m3 Dynamic Design
Manufacture
Density (Input)
r datasheet
Constant
APH Heat Air Preheater
W/m2*d from
47 Transfer SectionHeat Transfer Dynamic Design
eg C Manufacture
Coeff. Coeff. (Input)
r datasheet
Constant
Convection Section
CS Design from
48 Design Tube Flow kg/hr Dynamic Design
Tube FLow Manufacture
(Input)
r datasheet
Constant
CS Tube Convection Tube from
49 m2 Dynamic Design
Area Area (Input) Manufacture
r datasheet
Constant
CS Tube Convection Tube
from
50 Product Product Density kg/m3 Dynamic Design
Manufacture
Density (Input)
r datasheet
Constant
CS Heat Convection
W/m2*d from
51 Transfer SectionHeat Transfer Dynamic Design
eg C Manufacture
Coeff Coeff (Input)
r datasheet
Constant
HEX Design HEX Design Duty from
52 kW Dynamic Design
Duty (Input) Manufacture
r datasheet
Constant
Fuel Gas to
Furnace Fuel Gas to from
53 Product Dynamic Design
Product Ratio (Input) Manufacture
Ratio
r datasheet
Constant
HEX Load HEX Load Constant
54 Dynamic Design from
Constant A A (Input)
Manufacture

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 S Attribute Monitoring
Attribute Description Units Source
no Category Category

r datasheet

Constant
HEX Load HEX Load Constant from
55 Dynamic Design
Constant B B (Input) Manufacture
r datasheet
Constant
HEX Load HEX Load Constant from
56 Dynamic Design
Constant C C (Input) Manufacture
r datasheet
Constant
Radiant Section
RS Design from
57 Design Tube Flow kg/hr Dynamic Design
Tube FLow Manufacture
(Input)
r datasheet
Constant
RS Tube Radiation Tube Area from
58 m2 Dynamic Design
Area (Input) Manufacture
r datasheet
Constant
RS Tube Radiation Tube
from
59 Product Product Density kg/m3 Dynamic Design
Manufacture
Density (Input)
r datasheet
Constant
RS Heat Radiation
W/m2*d from
60 Transfer SectionHeat Transfer Dynamic Design
eg C Manufacture
Coeff. Coeff (Input)
r datasheet
Fuel
Gas Fuel Gas Fuel
61 % Dynamic Compositio Lab Analysis
C2H6 C2H6(Input)
n
Fuel
Gas Fuel Gas Fuel
62 % Dynamic Compositio Lab Analysis
C3H8 C3H8(Input)
n
Gas Fuel Fuel
Gas Fuel C4H10
63 C4H10 (n/i- % Dynamic Compositio Lab Analysis
(n/i-C4H10)(Input)
C4H10) n
Fuel
Gas Fuel Gas Fuel
64 % Dynamic Compositio Lab Analysis
C4H8 C4H8(Input)
n
Fuel
Gas Fuel Gas Fuel
65 % Dynamic Compositio Lab Analysis
C5H12 C5H12(Input)
n
Fuel
Gas Fuel Gas Fuel
66 % Dynamic Compositio Lab Analysis
C6H14 C6H14(Input)
n

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 S Attribute Monitoring
Attribute Description Units Source
no Category Category

Fuel
Gas Fuel Gas Fuel
67 % Dynamic Compositio Lab Analysis
C6H6 C6H6(Input)
n
Fuel
Gas Fuel Gas Fuel
68 % Dynamic Compositio Lab Analysis
C7H8 C7H8(Input)
n
Fuel
Gas Fuel
69 Gas Fuel CH4(Input) % Dynamic Compositio Lab Analysis
CH4
n
Fuel
70 Gas Fuel CO Gas Fuel CO(Input) % Dynamic Compositio Lab Analysis
n
Fuel
Gas Fuel
71 Gas Fuel CO2(Input) % Dynamic Compositio Lab Analysis
CO2
n
Fuel
72 Gas Fuel H2 Gas Fuel H2(Input) % Dynamic Compositio Lab Analysis
n
Fuel
Gas Fuel Gas Fuel
73 % Dynamic Compositio Lab Analysis
H2Ov H2Ov(Input)
n
Fuel
Gas Fuel
74 Gas Fuel H2S(Input) % Dynamic Compositio Lab Analysis
H2S
n
Fuel
75 Gas Fuel N2 Gas Fuel N2(Input) % Dynamic Compositio Lab Analysis
n
Fuel
76 Gas Fuel O2 Gas Fuel O2(Input) % Dynamic Compositio Lab Analysis
n
Fuel
Gas Fuel
77 Gas Fuel SO2(Input) % Dynamic Compositio Lab Analysis
SO2
n
APH Tube
Air Preheater Tube
Inlet J/kg*deg Thermo
78 Inlet Specific Heat Dynamic Constant
Specific C Properties
(Input)
Heat
APH Tube
Air Preheater Tube
Outlet J/kg*deg Thermo
79 Outlet Specific Heat Dynamic Constant
Specific C Properties
(Input)
Heat
CS Tube Convection Tube
J/kg*deg Thermo
80 Inlet Inlet Specific Heat Dynamic Constant
C Properties
Specific (Input)

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 S Attribute Monitoring
Attribute Description Units Source
no Category Category

Heat

CS Tube
Convection Tube
Outlet J/kg*deg Thermo
81 Outlet Specific Heat Dynamic Constant
Specific C Properties
(Input)
Heat
RS Tube
Inlet Radiation Tube Inlet J/kg*deg Thermo
82 Dynamic Constant
Specific Specific Heat (Input) C Properties
Heat
RS Tube
Radiation Tube
Outlet J/kg*deg Thermo
83 Outlet Specific Heat Dynamic Constant
Specific C Properties
(Input)
Heat
Air Inlet Air Inlet Specific
Thermo
84 Specific Heat (Internal kJ/kg-C Dynamic Calculated
Properties
Heat calculation)
Air Outlet Air Outlet Specific
Thermo
85 Specific Heat (Internal kJ/kg-C Dynamic Calculated
Properties
Heat calculation)
Combustion Air
Combustion Thermo
86 Density (Internal kg/m3 Dynamic Calculated
Air Density Properties
calculation)

Note
The Uniformance Asset Sentinel process and equipment monitoring models require thermodynamic
properties such as enthalpy, entropy, density, and specific heat to be calculated.
There are two options available to compute thermodynamic properties:
o Native Uniformance Asset Sentinel Thermodynamic models uses Be
o Linked UniSim Thermodynamic models

For evaluating gas properties for fired heater inlet and outlet streams, please refer the procedure for
configuring stream assets.

Model Output data

Attribut
S
e Monitoring
n Attribute Description Units Source
Categor Category
o
y

Air to Fuel Gas

1 Air to Fuel Ratio Stoichiometric Dynamic Performance Calculated
Ratio(Output)

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 2 Furnace Load Furnace Load(Output) % Dynamic Performance Calculated
Shutdown Shutdown Revenue Loss
3 kg/hr Dynamic Performance Calculated
Revenue Loss (Output)
CS Heat Transfer Convection Section Heat
4 % Dynamic Performance Calculated
Efficiency Transfer Efficiency(Output)
Furnace Furnace Input/Output
5 % Dynamic Performance Calculated
Efficiency Efficiency(Output)
Furnace Revenue Furnace Revenue
6 USD Dynamic Performance Calculated
Loss Loss(Output)
Maintenance Furnace Maintenance
7 USD Dynamic Performance Calculated
Revenue Loss Revenue Loss(Output)
8 Excess Air Excess Air(Output) % Dynamic Performance Calculated
RS Heat Transfer Radiation Section Heat
9 % Dynamic Performance Calculated
Efficiency Transfer Efficiency(Output)
Furnace Furnace Expected Duty
10 kW Dynamic Energy Calculated
Expected Duty (Output)
11 Total Heat Input Total Heat Input (Output) kW Dynamic Energy Calculated
Total Heat
12 Total Heat Output (Output) kW Dynamic Energy Calculated
Output
13 Duty Loss Duty Loss (Output) kW Dynamic Energy Calculated
Fuel
Fuel Compensation for
14 Compensation kg/hr Dynamic Energy Calculated
Duty Loss (Output)
for Duty Loss
CS Fouling Convection Section Fouling
15 % Dynamic Energy Calculated
Percentage Percentage(Output)

Convection Section Heat kilowatts/sq

16 CS Heat Flux Dynamic Energy Calculated
Flux(Output) uare_metre

Furnace Heat kilowatts/sq

17 Furnace Heat Flux(Output) Dynamic Energy Calculated
Flux uare_metre

RS Fouling Radiation Section Fouling

18 % Dynamic Energy Calculated
Percentage Percentage(Output)

Radiant Section Heat kilowatts/sq

19 RS Heat Flux Dynamic Energy Calculated
Flux(Output) uare_metre

Configuring a Fired Heater in Uniformance Asset Sentinel

To configure a fired heater asset with performance model

Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter
AS_FiredHeater.

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Model Library Guide 173
 Cartridge Filter Monitoring

Cartridge filters are used for filtration purpose which uses filtration technology of removing solid matter
and suspended impurities from a fluid stream by passing it through a variety micro porous filters,
ultrafiltration units, sand cartridge filters, activated carbon cartridge filters etc.

A cartridge filter consists of one or more filter cartridges, which slot into a housing. Cartridges can be
made of a rigid or flexible material. They have to be thrown away when they become blocked.

This document explains cartridge filter monitoring philosophy for process, performance, energy and
health parameters and their importance.

Item Type
Category Equipment
Equipment Class Filters
Equipment Type Cartridge Filter

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18.1 Process Performance Monitoring
The following measured parameters are monitored as they have impact on performance and health of
Cartridge filters, if not maintained in operating range.

Suction Pressure: The suction pressure of cartridge filter affects yarn hairiness and compactness. As
the suction pressure increases, the fibers are tightly pressed over filter with less slippage. Therefore, yarn
diameter decreases due to more transverse force on surface fibers. Therefore, more compact structure of
the yarn has been formed with less diameter, Result in higher flow rate.

Filter Flow: It is useful to keep records of the flow that has passed through a filter to get a feel for how
long a cartridge will last and when it may need replacing.

Discharge Pressure: Higher discharge pressure restricts flow of fluid through filter at same time it
causes solid unloading from filter and fluid migration. Therefore, pressure drop across filter is closely
monitor by operator for deciding changeover of filter.

Process Performance Overview: Process Performance monitoring view in UAS provides a list of the
asset attributes and their details, including the current value. This list can be used to review and update
asset attribute information, as well as to open an Asset Trend to view more details. It also highlights (in
red color) the attributes if deviates from the high or low limits.

18.2 Performance Monitoring

The effective utilization of the equipment can be monitored with the help of performance indicators.

Key Performance Indicators

The following indicators help us to know overall performance of the Cartridge filter.

Differential Pressure
This indicates the pressure drop across the filter. The rise in differential pressure indicates deterioration
of filter performance.

dP = P1 – P2

Where,

P1= Pressure at filter Inlet

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 P2= Pressure at filter Outlet

Percentage clogging
This indicates current clogging in the filter. Above 80% clogging, the filter elements are recommended
to clean or replace. Clogging is calculated by comparing design flow, pressure drop with current
operating conditions.

Rated Flowrate * (Actual Pressure drop - Housing Pressure

%Clogging =
drop)
*100
Actual Flowrate * Max allowable pressure drop

Housing Pressure drop = Fluid Constant*Fluid density*Flow rate

Performance Overview
Equipment Key Performance Indicators (KPIs) view in UAS provides a list of KPIs and their details,
including the current value. This list can be used to review and update asset attribute information, as well
as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if deviates
from the high or low limits.

18.3 Failure Modes

In Uniformance Asset Sentinel, you can configure faults, symptoms, and fault models on Cartridge Filter
performance output to diagnose the problems early. The fault management can inform operators of any
violations of the nominal Cartridge Filter operating range and deviations from the expected
characteristic and make this data available for further processing through the historian. The fault
symptoms or models are used to:
o Warn against potential damage to Cartridge Filter under unfavorable operating conditions.
o Provide early warning of damages to the Cartridge Filter.

The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions
o Higher differential pressure
o High filter clogging
o Incoming fluid too dirty
o Sudden changes in flow rate to a filter

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 o Changing cartridges too late
o Cartridge pore size is too large
o Cartridge not seated or installed correctly
o Cartridge is starting to unload
o Cartridge has ruptured (sudden loss in differential pressure)
o By concentrating particles in one area

Below table illustrates the list of faults and symptoms configured for a Cartridge Filter to identify
possible anomalies that affects the performance or health of a Cartridge Filter.

Fault
Fault Name Associated Symptoms
Category

Performance Performance Degradation Warning Filter Differential Pressure High

Health Health Degradation Warning Filter Clogging High

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

18.4 Configuration
As described in previous sections, Cartridge Filter performance monitoring model is used to:
o Calculate the current operating point data such as head, power consumed, and NPSH. The
calculation is performed based on the inputs received from DCS/Historian or based on the
configured model parameters.
o Interpolate or extrapolate the design data for the current operating FlowRate from the
Manufacturer performance curve.

The calculation model to perform as expected, it requires some inputs are to be feed into the model. The
Cartridge Filter model input data consists of measured data and static data. Measured input data is
supplied to the model from DCS or Historian by tag mapping. This section describes the list of input and
output attributes and its properties.

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Model Input data

S Attribute Monitoring
Attribute Description Units Source
no Category Category

Rated Air Rated Air Flow

1 Field Input
Flow (Input) Static Design
Reference Reference Density Thermo
2 barg Field Input
Density (Input) Static Properties
Suction Suction Pressure
3 deg C Field Input
Pressure (Input) Dynamic Process
Discharge Discharge Pressure
4 deg C Field Input
Pressure (Input) Dynamic Process
Volumetric Volumetric Flow Rate
5 m3/hr Field Input
Flow Rate (Input) Dynamic Process
Fluid Thermo
6 barg Field Input
Density Fluid Density (Input) Dynamic Properties

Model Output data

S Attribute Monitoring
Attribute Description Units Source
no Category Category

Filter Calculated
1 Relative Filter Relative
Clogging Clogging (Output) Dynamic Performance
Filter Actual Filter Actual DP Calculated
2
DP (Output) Dynamic Performance

Configuring a Cartridge Filter in Uniformance Asset Sentinel

To configure a Cartridge Filter asset

Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter
Cartridge Filter.

Refer to the following procedures:

o To configure asset connection attributes.
o To map a dynamic attribute to the datasource tags.
o To set the attribute properties for the Attribute Viewer and Performance Overview.
o To manually update asset attribute information.

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 Reciprocating Compressor
Monitoring

A reciprocating compressor is a positive-displacement compressor that uses pistons driven by a

crankshaft to deliver gases at high pressure. The inlet gas enters the suction manifold, then flows into
the compression cylinder where it gets compressed by a piston driven in a reciprocating motion via a
crankshaft, and is then discharged. Reciprocating compressors are typically used where high
compression ratios (ratio of discharge to suction pressures) are required per stage without high flow
rates, and the process fluid is relatively dry.

This document explains ESP monitoring philosophy for process, performance, energy and health
parameters and their importance.

Item Type
Category Equipment
Equipment Class Compressors
Equipment Type AS_Piston_Compressor

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19.1 Process Performance Monitoring
The following measured parameters are monitored as they have impact on performance and health of
Reciprocating compressor, if not maintained in operating range.

Suction Temperature: Inlet temperature changes produce large changes in performance. Lower
Temperature increases the capacity (weight flow) at a given discharge pressure and hence increases
power consumption. Whereas Higher Temperature decreases the capacity (weight flow) at a given
discharge pressure and decreases power consumption.

Suction Pressure: Lower inlet pressure decreases the capacity (weight flow) and decreases power
consumption due to reduced weight flow.

Discharge Temperature: If the compressor discharge temperature is very high then it may result in
breakdown of the lubricating oil, causing excessive wear and reduced life of the compressor valves
(mainly the discharge valve). When the temperature is high, undesirable chemical reactions may take
place inside the compressor, especially in the presence of water. This may ultimately damage the
compressor.

Discharge Pressure: Changes in discharge pressure have effect on cylinder capacity and compression
ratio. Volumetric efficiency varies slightly with compression ratio, and the required power is directly
proportional to the change in compression ratio.

Volumetric Flow Rate: Volumetric flow is key parameter for calculating volumetric efficiency of
compressor hence, as volumetric flow decreases it decrease volumetric efficiency of reciprocating
compressor and vice versa.

Process Performance Overview: Process Performance monitoring view in UAS provides a list of the
asset attributes and their details, including the current value. This list can be used to review and update
asset attribute information, as well as to open an Asset Trend to view more details. It also highlights (in
red color) the attributes if deviates from the high or low limits.

19.2 Performance Monitoring

The effective utilization of the equipment can be monitored with the help of performance indicators.

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Model Library Guide 180
Key Performance Indicators
The following indicators help us to know overall performance of the compressor.

Operating Volumetric Efficiency

This is the ratio of actual volume of gas (at inlet conditions) delivered to the piston displacement of the
compressor. The piston displacement or the swept volume is the net volume actually displaced by the
piston at rated machine speed.

For Single Acting Compressor,

Piston Displacement(m3/hr) = PI/4*D*N*S*60

For Double Acting Compressor,

Piston Displacement(m3/hr) = PI/4*(D+D-d)*N*S*60

Where,

D=diameter of piston(m)

N=Speed of compressor(rpm)

S=Stroke(m)

d=diameter of piston rod(m)

In case of double acting compressor, the piston displacement gets doubled. However, on one side the
displacement get reduced by volume occupied by piston rod. The volumetric efficiency obtained by
above method indicates the condition of compressor in operation.

However, during design stage this efficiency has to be estimated to determine the expected capacity
from the cylinder.
1
𝜂𝜂𝑉𝑉𝑉𝑉𝑉𝑉 = 0.97 − 𝐶𝐶 ∗ �𝑃𝑃 ∗ 𝑅𝑅 𝐾𝐾 − 1� − 𝐿𝐿

Where,

C= Clearance percentage of piston displacement. The manufacturer usually provides this value for each
end of cylinder in the datasheet. This is normally around 15%. However, widely different percentages are
also possible.

K= ratio of the gas specific heat capacities

L=Typically leakage losses, are assumed to be 0.03 to 0.05 for lubricated compressors and 0.07 to 0.1
for non-lubricated compressors. It is also function of suction pressure. When the suction pressure is
high, the losses can be higher.

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Model Library Guide 181
Operating Isentropic Efficiency
Isentropic efficiency is ratio of isentropic head to measured head.

Isentropic Head
Isentropic Efficiency = *100
Measured Head
H2isen − H1
Isentrohic Efficiency = ∗ 100
H2 − H1

Where,

𝐻𝐻1 = Suction enthalpy calculated at P1, T1, and composition (zi)

𝐻𝐻2 = Discharge enthalpy calculated at P2, T2, and composition (zi)

𝐻𝐻2𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 = Isentropic discharge enthalpy at P2 (or T2)

Operating Shaft Efficiency

Operating shaft efficiency is calculated as follows

Compressor Power
Shaft Efficiency = *100
(Compressor Driver Power*Mech
Efficiency)

Compressor Load
Compressor load is calculated as follows

Compressor Load CompressorPower*MechanicalEfficiency

*100
=
MaximumRatedPower

Shaft Power
Shaft power is actual power received by compressor at its coupling. This can be calculated as follows,
K−1
2.78 ∗ 10−4 K P2 K
PShaft = ∗� � ∗ Q V ∗ P1 [� � − 1]
η K−1 P1

Where,

𝑃𝑃𝑆𝑆ℎ𝑎𝑎𝑎𝑎𝑎𝑎 = Shaft Power (kW)

𝜂𝜂 = Efficiency

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𝑃𝑃1 , 𝑃𝑃2 = Absolute inlet pressure ,kPa

𝑄𝑄𝑉𝑉 =Volumetric flow rate of gas based on inlet condition, m3/h

K= Cp/Cv

Performance Overview
Equipment Key Performance Indicators (KPIs) view in UAS provides a list of KPIs and their details,
including the current value. This list can be used to review and update asset attribute information, as
well as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if
deviates from the high or low limits.

19.3 Failure Modes

In Uniformance Asset Sentinel, you can configure faults, symptoms, and fault models on Reciprocating
Compressor performance output to diagnose the problems early. The fault management can inform
operators of any violations of the nominal Reciprocating Compressor operating range and deviations
from the expected characteristic and make this data available for further processing through the
historian. The fault symptoms or models are used to:
o Warn against potential damage to Reciprocating Compressor under unfavorable operating
conditions.
o Provide early warning of damages to the Cartridge Filter.

The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions
o Liquid Carryover
o Gas leakage
o Excessive discharge temperature
o Valve Leakages & Blockages
o Improper lubrication
o Shaft damage
o Bearing Temperature High
o Startup and shut down problems

Below table illustrates the list of faults and symptoms configured for a pump to identify possible
anomalies that affects the performance or health of a pump.

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Model Library Guide 183
 Fault
Fault Name Associated Symptoms
Category

Compressor Isentropic Efficiency Low

Performance Performance Degradation Warning
Compressor Volumetric Efficiency Low

Discharge Pressure High

Discharge Pressure Low

Health Health Degradation Warning
Compressor Load High

Compressor Load Low

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

19.4 Configuration
As described in previous sections, Reciprocating Compressor performance monitoring model is used to:
o Calculate the current operating point data such as head, power consumed, and NPSH. The
calculation is performed based on the inputs received from DCS/Historian or based on the
configured model parameters.
o Interpolate or extrapolate the design data for the current operating FlowRate from the
Manufacturer performance curve.

The calculation model to perform as expected, it requires some inputs are to be feed into the model. The
Reciprocating Compressor model input data consists of measured data and static data. Measured input

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Model Library Guide 184
data is supplied to the model from DCS or Historian by tag mapping. This section describes the list of
input and output attributes and its properties.

Model Input data

S Attribute Monitoring
Attribute Description Units Source
no Category Category

Piston Bore Piston Bore

1 Constant
Diameter Diameter (Input) m Dynamic Design
2 Clearence Clearence (Input) % Dynamic Design Constant
Stage Constant
3 Cylinder Stage Cylinder
Number Number (Input) Dynamic Design
Suction
4 Specific Suction Specific Thermo Field Input
Heat Heat (Input) kJ/kg-C Dynamic Properties
Discharge
5 Specific Discharge Specific Thermo Field Input
Heat Heat (Input) kJ/kg-C Dynamic Properties
Mechanical Mechanical
6 Field Input
Efficiency Efficiency (Input) % Static Design
7 Gear Ratio Gear Ratio (Input) Static Design Constant
Adiabatic Suction Adiabatic Thermo
8 Constant
Exponent K1 Exponent K1 (Input) Dynamic Properties
Piston Rod Piston Rod Diameter
9 Constant
Diameter (Input) m Dynamic Design
Piston
10 Stroke Piston Stroke Length Constant
Length (Input) m Dynamic Design
Z1
11 (compressib Z1 (compressibility Thermo Constant
ility inlet) inlet) Dynamic Properties
Suction Suction Pressure Field Input
12
Pressure (Input) barg Dynamic Process
Discharge Discharge Pressure Field Input
13
Pressure (Input) barg Dynamic Process
Compressor Compressor Field Input
14 Volumetric Volumetric Flow
Flow (Input) m3/hr Dynamic Process
Shaft Field Input
15 Rotation Shaft Rotation Speed
Speed (Input) rpm Dynamic Process
Piston Piston Stroke % Field Input
16
Stroke % (Input) % Dynamic Design
17 Suction Suction Temperature deg C Dynamic Process Field Input

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 S Attribute Monitoring
Attribute Description Units Source
no Category Category

Temperature (Input)
Discharge Discharge
18 Field Input
Temperature Temperature (Input) deg C Dynamic Process

Model Output data

S Attribute Monitoring
Attribute Description Units Source
no Category Category

Isentropic Isentropic Efficiency Calculated

1
Efficiency (Output) % Dynamic Performance
Compressor Compressor Load Calculated
2
Load (Output) % Dynamic Performance
Shaft Shaft Efficiency Calculated
3
Efficiency (Output) % Dynamic Performance
Operating Operating Shaft Calculated
4
Shaft Power Power (Output) kW Dynamic Performance
Volumetric Volumetric Efficiency Calculated
5
Efficiency (Output) % Dynamic Performance

Configuring a Reciprocating Compressor in Uniformance

Asset Sentinel
To configure a Reciprocating Compressor asset

Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter
AS_Piston_Compressor.

Refer to the following procedures:

o To configure asset connection attributes.
o To map a dynamic attribute to the datasource tags.
o To set the attribute properties for the Attribute Viewer and Performance Overview.
o To manually update asset attribute information.

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 Gas Turbine Monitoring

Gas Turbine is mainly used to generate power from the gases by burning the fuel in the combustor in the
presence of compressed air. The fuels considered are natural gas, diesel oil, and so on. Gas turbines
convert fuel energy into mechanical power (or) by connecting to electric generators - electric power.

The underlying thermodynamic cycle, known as the Brayton Cycle, involves the compression of a
gaseous medium (typically air), the addition of fuel energy through combustion or heat exchange and
expansion of the hot compressed gas through a turbine to convert the thermal energy into shaft power.
In contrast to an ideal thermodynamic cycle, a real gas turbine cannot perform these processes free of
friction and losses. The profitability of the gas turbine process is related to the efficiency (shaft power
generated per unit fuel consumption). The importance of maximizing efficiency is thus evident.

This document explains Gas turbine monitoring philosophy for process, performance, energy and health
parameters and their importance.

Item Type
Category Equipment
Equipment Class Turbine
Equipment Type Gas Turbine/HRSG

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20.1 Process Performance Monitoring
The following measured parameters are monitored as they have impact on performance and health of
Cartridge filters, if not maintained in operating range.

Turbine Inlet Pressure and Temperature: The power output of a gas turbine is a function of turbine inlet
temperature. The turbine inlet temperature (TIT) plays an important role on the performance of combined
cycle. The maximum value of TIT is fixed due to the metallurgical problem of turbine blade cooling. TIT
should be kept on the higher side, because at lower values, the exergy destruction is higher. High
pressure and high temperature at the turbine inlet, reduces the durability of the gas path component and
thereby reduces the turbine efficiency. However, to achieve the thermal efficiencies delivered by modern
gas turbines, they must work at process conditions that push the mechanical and thermal stress of the
materials used in the machine’s gas path components to their limits. High temperature and low pressure
at the compressor inlet, reduces the mass flow that can be generated through the turbine.

Humidity: Higher specific humidity increases the specific volume of the inlet air flow, so that the mass
flow through the turbine is reduced resulting in less power output and increased heat rate.

Turbine Outlet Pressure: At the turbine outlet, High pressure (either exhausting into a stack, or a heat
recovery steam generator in combined cycle plants) reduces the energy that can be converted to shaft
power.

Load: If the gas turbine is not operated at its optimal load level, the flow triangles in the compressor and
turbine expander stages will differ from design assumptions and thereby more energy will be dissipated.

Compressor pressure ratio: The temperature of air leaving the compressor and entering in combustion
chamber depends upon the compressor pressure ratio. As the compression ratio increases, the air exiting
the compressors is hotter, therefore less fuel is required (lowering the air fuel ratio) to reach the desired
turbine inlet temperature, for a fixed gas flow to the gas turbine. The work required in the compressor and
the power output of the gas turbine, steadily increases with compression ratio, then cause decreases in
the exhaust gases temperature. This lower gas temperature causes less steam to be produced in the
HRSG, therefore lowering the outputs of the steam cycle.

Fuel heating value: It depend on the content of energy per mass unit of fuel injected along with steam or
water into the combustors which help to boost power output and to control NOx emission level.

Steam Drum Level: There are Steam bubbles under water in drum, these bubbles are affected by
pressure changes and have a big effect on drum level.

Process Performance Overview: Process Performance monitoring view in UAS provides a list of the
asset attributes and their details, including the current value. This list can be used to review and update
asset attribute information, as well as to open an Asset Trend to view more details. It also highlights (in
red color) the attributes if deviates from the high or low limits.

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20.2 Performance Monitoring
The effective utilization of the equipment can be monitored with the help of performance indicators.

Key Performance Indicators

The following indicators help us to know overall performance of the compressor.

Thermal Efficiency

Output Power(kW) × 3600

Thermal Efficiency =
Input Energy (kJ/hr)

Input Energy (kJ/hr) = Fuel Consumption (Kg/Hr) × Fuel Calorific Value LHV(KJ/Kg)

Output Power(kW) = Net Output Form Gas turbine.

Heat Rate

Input Energy (kJ/hr)

Heat Rate (KJ/KWhr) =
Output Power(kW)

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Compressor Polytropic Efficiency
The efficiency relates the actual work done on the gas (during compression process) to the total work
input into the compression system (from the driver, including losses etc.) For real gases, the
recommended approach to derive the efficiency using enthalpy difference between the suction enthalpy
and discharge enthalpy and Polytropic head.

Polytropic Head
Polytropic Efficiency (%) = × 100
Measured Head

The operating head is calculated from the enthalpy of input and outlet process stream:

Measured Head (m) = Measured Discharge Enthalpy(KJ/Kg) – Measured Suction Enthalpy(KJ/Kg)

Measured Discharge Enthalpy(KJ/Kg) = Enthalpy at Discharge temperature and pressure.

Measured Suction Enthalpy(KJ/Kg) = Enthalpy at Suction temperature and pressure

Note

Detailed calculation of compressor Poly Efficiency is available in compressor document.

Performance Overview
Equipment Key Performance Indicators (KPIs) view in UAS provides a list of KPIs and their details,
including the current value. This list can be used to review and update asset attribute information, as
well as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if
deviates from the high or low limits.

20.3 Failure Modes

In Uniformance Asset Sentinel, you can configure faults, symptoms, and fault models on Gas Turbine
performance output to diagnose the problems early. The fault management can inform operators of any
violations of the nominal Gas Turbine operating range and deviations from the expected characteristic

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and make this data available for further processing through the historian. The fault symptoms or models
are used to:
o Warn against potential damage to Gas Turbine under unfavorable operating conditions.
o Provide early warning of damages to the Cartridge Filter.

The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions
o Low compressor efficiency: It is determined by means of the deviation of the current compressor
efficiency from the efficiency characteristic.
o Tip Rubs: Blade-to-case rub can degrade the performance of Gas Turbines through the
introduction of high amplitude shaft vibration and severe blade/seal wear. It can even lead to
catastrophic failure in the worst occurrence.
o Fouling: It is an important factor in Gas Turbines, caused due to deposition of material on the
surfaces. The gas turbine effective performance decreases when fouling occurs. Fouling predictions
are used to predict the maintenance schedules for cleaning Gas Turbines.

Below table illustrates the list of faults and symptoms configured for a gas turbine to identify possible
anomalies that affects the performance or health of a gas turbine.

Fault
Fault Name Associated Symptoms
Category

GT Thermal Efficiency Low

GT Outlet Temp High
GT Fuel Quality Low
GT Speed Low
Performance Gas Turbine Performance Warning
GT Stack Oxygen High
GT Enclosure Temp High
GT Stack NOx High
GT Uneven Temperature Spread High
GT Compressor Efficiency Low
Health Compressor Performance Warning
Inlet Air Filter Clogged

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

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20.4 Configuration
As described in previous sections, Gas Turbine performance monitoring model is used to:
o Calculate the current operating point data such as head, power consumed, and NPSH. The
calculation is performed based on the inputs received from DCS/Historian or based on the
configured model parameters.
o Interpolate or extrapolate the design data for the current operating FlowRate from the
Manufacturer performance curve.

The calculation model to perform as expected, it requires some inputs are to be feed into the model. The
Gas Turbine model input data consists of measured data and static data. Measured input data is
supplied to the model from DCS or Historian by tag mapping. This section describes the list of input and
output attributes and its properties.

Model Input data

Attribute Monitoring
S No Attribute Description Units Source
Category Category

Air Bell Mouth Static

Pressure or Pressure Drop
(Required Input, if air inlet
volume flow rate and GT
Air Bell Mouth Static measured shaft power are Field
1 Pressure not given) barg Dynamic Process Input
AirInletVolumeFlowRate
(Required Input, if air Bell
Air Inlet Volume Flow Mouth static pressure and Field
2 Rate GT measured shaft power m3/hr Dynamic Process Input

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 Attribute Monitoring
S No Attribute Description Units Source
Category Category
are not given)

Ambient Relative Humidity Field

3 Relative Humidity (Input) % Dynamic Process Input
Ambient Temperature Field
4 Ambient Temperature (Input) deg C Dynamic Process Input
Field
5 Barometric Pressure Barometric Pressure (Input) bara Dynamic Process Input
Combustor Jacket Combustor Jacket Heat Field
6 Heat Loss Loss (Input) kJ/hr Dynamic Internal Input
Combustor PresLoss Combustor Pressure Loss Field
7 Factor Factor (Input) Static Design Input
Combustor Rated Combustor Rated Efficiency Field
8 Efficiency (Input) % Static Design Input
Compressor Compressor Discharge Field
9 Discharge Pressure Pressure (Required Input) barg Dynamic Process Input
Compressor Compressor Discharge
Discharge Temperature (Required Field
10 Temperature Input) deg C Dynamic Process Input
Compressor Discharge
Compressor Pressure Correction Factor Field
11 DisPresCorrFactor (Input) Static Internal Input
Compressor Guide Vane
Compressor Guide Position (Required Input for Field
12 Vane Position variable guide vane option) Degrees Dynamic Process Input
Compressor Inlet Area at
IGV (Required Input, if air
inlet volume flow rate and
GT measured shaft power Field
13 Compressor Inlet Area are not given) m2 Static Design Input
Compressor Inlet Compressor Inlet Pressure Field
14 Pressure (Input) barg Dynamic Process Input
Compressor Inlet Compressor Inlet Field
15 Temperature Temperature (Input) deg C Dynamic Process Input
Compressor Compressor Mechanical Field
16 Mechanical Efficiency Efficiency (Input) % Static Design Input
Compressor Type (Input as
1-Constant Speed and
Constant Guide Vane Pos
(default), 2- Constant
Speed Variable Guide Vane Field
17 Compressor Option Pos, 3-Variable Speed) Static Design Input
Compressor Recycle Bleed
Compressor Recycle Fraction for Inlet Heating Field
18 Bleed Fraction (Input) Dynamic Internal Input

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 Attribute Monitoring
S No Attribute Description Units Source
Category Category

Field
19 Diffusor Heat Loss Diffusor Heat Loss (Input) kJ/hr Dynamic Internal Input
Diffusor Pressure Loss Diffusor Pressure Loss Field
20 Factor Factor (Input) Static Internal Input
Argon Mole Percent in Fuel Fuel Field
21 Fuel_Argon (Input) % Dynamic Composition Input
Ash Mole Percent in Fuel Fuel Field
22 Fuel_Ash (Input) % Dynamic Composition Input
Butane Mole Percent in Fuel Field
23 Fuel_Butane Fuel (Input) % Dynamic Composition Input
Butene Mole Percent in Fuel Field
24 Fuel_Butene Fuel (Input) % Dynamic Composition Input
Carbon Dioxide Mole Fuel Field
25 Fuel_CarbonDioxide Percent in Fuel (Input) % Dynamic Composition Input
Carbon Monoxide Mole Fuel Field
26 Fuel_CarbonMonoxide Percent in Fuel (Input) % Dynamic Composition Input
Decane Mole Percent in Fuel Field
27 Fuel_Decane Fuel (Input) % Dynamic Composition Input
Ethane Mole Percent in Fuel Field
28 Fuel_Ethane Fuel (Input) % Dynamic Composition Input
Ethylene Mole Percent in Fuel Field
29 Fuel_Ethylene Fuel (Input) % Dynamic Composition Input
Helium Mole Percent in Fuel Field
30 Fuel_Helium Fuel (Input) % Dynamic Composition Input
Heptane Mole Percent in Fuel Field
31 Fuel_Heptane Fuel (Input) % Dynamic Composition Input
Hexane Mole Percent in Fuel Field
32 Fuel_Hexane Fuel (Input) % Dynamic Composition Input
Hydrogen Mole Percent in Fuel Field
33 Fuel_Hydrogen Fuel (Input) % Dynamic Composition Input
Hydrogen Sulfide Mole Fuel Field
34 Fuel_HydrogenSulfide Percent in Fuel (Input) % Dynamic Composition Input
IsoButane Mole Percent in Fuel Field
35 Fuel_IsoButane Fuel (Input) % Dynamic Composition Input
IsoPentane Mole Percent in Fuel Field
36 Fuel_IsoPentane Fuel (Input) % Dynamic Composition Input
Methane Mole Percent in Fuel Field
37 Fuel_Methane Fuel (Input) % Dynamic Composition Input
Nitrogen Mole Percent in Fuel Field
38 Fuel_Nitrogen Fuel (Input) % Dynamic Composition Input
Nonane Mole Percent in Fuel Field
39 Fuel_Nonane Fuel (Input) % Dynamic Composition Input
40 Fuel_Octane Octane Mole Percent in % Dynamic Fuel Field

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 Attribute Monitoring
S No Attribute Description Units Source
Category Category
Fuel (Input) Composition Input

Oxygen Mole Percent in Fuel Field

41 Fuel_Oxygen Fuel (Input) % Dynamic Composition Input
Pentane Mole Percent in Fuel Field
42 Fuel_Pentane Fuel (Input) % Dynamic Composition Input
Propane Mole Percent in Fuel Field
43 Fuel_Propane Fuel (Input) % Dynamic Composition Input
Propylene Mole Percent in Fuel Field
44 Fuel_Propylene Fuel (Input) % Dynamic Composition Input
Sulfur Mole Percent in Fuel Fuel Field
45 Fuel_Sulfur (Input) % Dynamic Composition Input
Sulfur Dioxid Mole Percent Fuel Field
46 Fuel_SulfurDioxide in Fuel (Input) % Dynamic Composition Input
Water Mole Percent in Fuel Fuel Field
47 Fuel_Water (Input) % Dynamic Composition Input
Fuel Inlet Mass Flow Fuel Inlet Mass Flow Rate Field
48 Rate (Required Input) kg/hr Dynamic Process Input
Field
49 Fuel Inlet Pressure Fuel Inlet Pressure (Input) barg Dynamic Process Input
Fuel Inlet Temperature Field
50 Fuel Inlet Temperature (Input) deg C Dynamic Process Input
Fuel Lower Heating Value Field
51 Fuel LHV (Required Input) kJ/kg Static Process Input
GT Inlet Air Flow Corr Gas Turbine Inlet Air Flow Field
52 Factor Correction Factor (Input) Static Internal Input
GT Inlet Filter Pressure GT Inlet Filter Pressure Drop Field
53 Drop (Input) Dynamic Process Input
Gas Turbine Measured
Shaft Power or Power
Produced by Gas Turbine
(Required Input, if air inlet
volume flow rate and air Bell
GT Measured Shaft Mouth static pressure are Field
54 Power not given) kW Dynamic Process Input
Gas Turbine Outlet Pressure Field
55 GT Outlet Pressure (Required Input) barg Dynamic Process Input
Gas Turbine Outlet
GT Outlet Temperature (Required Field
56 Temperature Input) deg C Dynamic Process Input
Gas Turbine Rated Pressure
or Combustor Rated Field
57 GT Rated Pressure Pressure (Input) bara Static Design Input
Gas Turbine Rated Field
58 GT Rated Temperature Temperature or Combustor deg C Static Design Input

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 Attribute Monitoring
S No Attribute Description Units Source
Category Category
Rated Temperature (Input)

GT Reference Gas Turbine Reference Field

59 Molecular Weight Molecular Weight (Input) Static Design Input
Gas Turbine Reference Field
60 GT Reference Pressure Pressure (Input) bara Static Design Input
GT Reference Gas Turbine Reference Field
61 Temperature Temperature (Input) deg C Static Design Input
Nozzle Cooling Air Nozzle Cooling Air Fraction Field
62 Fraction (Input) Dynamic Internal Input
Rated Air Inlet Mass Flow
Rate (Required Input if air
BellMouth static pressure
Rated Air Mass Flow and air inlet volume flow Field
63 Rate rate are not given) kg/hr Static Design Input
Turbine Mechanical Turbine Mechanical Field
64 Efficiency Efficiency (Input) % Static Design Input
Turbine Nozzle Angle
(Required Input for Variable Field
65 Turbine Nozzle Angle Turbine Nozzle option) Degrees Dynamic Design Input
Turbine Type (Input as 1-
Fixed Nozzle (default), 2- Field
66 Turbine Option Variable Nozzle) Static Design Input
Turbine Power Loss Turbine Power Loss Factor Field
67 Factor (Input) Static Internal Input
Turbine Rated Speed Field
68 Turbine Rated Speed (Input) rpm Static Design Input
TurbineRotorPitchRadius
Turbine Rotor Pitch (Required Input for design Field
69 Radius calculations) m Static Design Input
Turbine Speed (Required Field
70 Turbine Speed Input) rpm Dynamic Process Input

Model Output data

S Attribute Monitoring
Attribute Description Units Source
No Category Category

Combustor
1 Efficiency Combustor Efficiency (Output) % Dynamic Internal Calculated
Combustor
Heat Of Combustor Heat Of Combustion
2 Combustion (Output) kJ/hr Dynamic Internal Calculated
Compressor Compressor Inlet Mass Flow Rate
3 Inlet of Air (Output) kg/hr Dynamic Internal Calculated

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 S Attribute Monitoring
Attribute Description Units Source
No Category Category
MassFlowRate

Design
Compressor
Discharge Design Compressor Discharge
4 Temp Temperature (Output) deg C Dynamic Performance Calculated
Design
Compressor Design Compressor Isentropic
5 Isen Efficiency Efficiency (Output) % Dynamic Performance Calculated
Design
Compressor Design Compressor Polytropic
6 Poly Efficiency Efficiency (Output) % Dynamic Performance Calculated
Design
Compressor Design Compressor Shaft Power
7 Shaft Power (Output) kW Dynamic Performance Calculated
Design Cycle
8 Heat Ratio Design Cycle Heat Ratio (Output) Dynamic Performance Calculated
Design GT Design Gas Turbine Heat Rate
9 Heat Rate (Output) kJ/kW-hr Dynamic Performance Calculated
Design GT Design Gas Turbine Shaft Power
10 Shaft Power (Output) kW Dynamic Performance Calculated
Design GT
Thermal Design Gas Turbine Thermal
11 Efficiency Efficiency (Output) % Dynamic Performance Calculated
Design
Turbine Design Turbine Efficiency
12 Efficiency (Output) % Dynamic Performance Calculated
Design
Turbine Inlet Design Turbine Inlet Temperature
13 Temperature (Output) deg C Dynamic Performance Calculated
Design
Turbine Jet Design Turbine Jet Velocity Ratio
14 Velocity Ratio (Output) Dynamic Performance Calculated
Design
Turbine Outlet Design Turbine Outlet
15 Temperature Temperature (Output) deg C Dynamic Performance Calculated
Design
Turbine Shaft Design Turbine Shaft Power
16 Power (Output) kW Dynamic Performance Calculated
Deviation
Compressor Deviation Compressor Discharge
Discharge Temperature between Operating
17 Temp and Design values (Output) deg C Dynamic Deviation Calculated
Deviation Deviation Compressor Isentropic
Compressor Efficiency between Operating and
18 Isen Eff Design values (Output) % Dynamic Deviation Calculated

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 S Attribute Monitoring
Attribute Description Units Source
No Category Category

Deviation Deviation Compressor Polytropic

Compressor Efficiency between Operating and
19 Poly Eff Design values (Output) % Dynamic Deviation Calculated
Deviation Deviation Cycle Heat Ratio
Cycle Heat between Operating and Design
20 Ratio values (Output) Dynamic Deviation Calculated
Deviation GT Deviation Gas Turbine Thermal
Thermal Efficiency between Operating and
21 Efficiency Design values (Output) % Dynamic Deviation Calculated
Deviation Deviation Turbine Efficiency
Turbine between Operating and Design
22 Efficiency values (Output) % Dynamic Deviation Calculated
Deviation Deviation Turbine Inlet
Turbine Inlet Temperature between Operating
23 Temperature and Design values (Output) deg C Dynamic Deviation Calculated
Deviation Deviation Turbine Outlet
Turbine Outlet Temperature between Operating
24 Temperature and Design values (Output) deg C Dynamic Deviation Calculated
25 Energy Index Energy Index (Output) Dynamic Internal Calculated
GT Exhaust
Spread GT Exhaust Spread Temperature
26 Temperature (Output) deg C Dynamic Process Calculated
GT Outlet
Volume Flow Gas Turbine Outlet Volume Flow
27 Rate Rate (Output) m3/hr Dynamic Internal Calculated
28 Health Index Health Index (Output) Dynamic Internal Calculated
Operating
Compressor Operating Compressor Isentropic
29 Isen Efficiency Efficiency (Output) % Dynamic Internal Calculated
Operating
Compressor Operating Compressor Polytropic
30 Poly Efficiency Efficiency (Output) % Dynamic Performance Calculated
Operating
Compressor Operating Compressor Shaft
31 Shaft Power Power (Output) kW Dynamic Performance Calculated
Operating
Cycle Heat Operating Cycle Heat Ratio
32 Ratio (Output) Dynamic Internal Calculated
Operating GT Operating Gas Turbine Heat Rate
33 Heat Rate (Output) kJ/kW-hr Dynamic Performance Calculated
Operating GT Operating Gas Turbine Shaft
34 Shaft Power Power (Output) kW Dynamic Performance Calculated
Operating GT Operating Gas Turbine Thermal
35 Thermal Efficiency (Output) % Dynamic Performance Calculated

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 S Attribute Monitoring
Attribute Description Units Source
No Category Category
Efficiency

Operating
Turbine Operating Turbine Efficiency
36 Efficiency (Output) % Dynamic Performance Calculated
Operating
Turbine Inlet Operating Turbine Inlet
37 Temp Temperature (Output) deg C Dynamic Performance Calculated
Operating
Turbine Outlet Operating Turbine Outlet
38 Temp Temperature (Output) deg C Dynamic Performance Calculated
Operating
Turbine Shaft Operating Turbine Shaft Power
39 Power (Output) kW Dynamic Performance Calculated
Percent
Deviation Percent Deviation Compressor
Compressor Shaft Power between Operating
40 Shaft Power and Design values (Output) % Dynamic Deviation Calculated
Percent Percent Deviation Gas Turbine
Deviation GT Heat Rate between Operating and
41 Heat Rate Design values (Output) % Dynamic Deviation Calculated
Percent
Deviation Percent Deviation Gas Turbine
GTShaft Shaft Power between Operating
42 Power and Design values (Output) % Dynamic Deviation Calculated
Percent
Deviation Percent Deviation Turbine Shaft
Turbine Shaft Power between Operating and
43 Power Design values (Output) % Dynamic Deviation Calculated
Performance
44 Index Performance Index (Output) Dynamic Internal Calculated
Turbine Inlet
Mass Flow Turbine Inlet Mass Flow Rate of
45 Rate Gas (Output) kg/hr Dynamic Internal Calculated
Turbine Inlet
46 Pressure Turbine Inlet Pressure (Output) barg Dynamic Process Calculated
Turbine Outlet
47 Pressure Turbine Outlet Pressure (Output) barg Dynamic Process Calculated

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Configuring a Gas Turbine Asset with Performance Model
To configure a Gas Turbine asset

Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter Gas
Turbine.

Refer to the following procedures:

o To configure asset connection attributes.
o To map a dynamic attribute to the datasource tags.
o To set the attribute properties for the Attribute Viewer and Performance Overview.
o To manually update asset attribute information.

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 Boiler Monitoring

A boiler is an enclosed vessel that provides a means for combustion heat to be transferred into water
until it becomes steam. Depending on industry requirement boiler generated steam can be utilized in
various applications like, power generation units, as a source of energy for unit operations, etc.

A survey shows that scope of savings in boiler house ranges from 28% to 46% for different
industries. Also, it indicated steam consumption increased by 16% when boiler efficiency is dropped by
10%.

The boiler system comprises of Combustor, BFW system, Steam drum, Blowdown and fuel system.

Combustor: The combustor is used to burn fuel with air to generate heat which will be used to heat
boiler feed water to generate steam or superheated steam.

BFW system: The boiler feed water system provides water to the boiler and regulates it automatically to
meet the steam demand.

Steam Drum: The steam drum collects and controls the steam produced in the boiler. Steam is directed
through a piping system to the point of use. Throughout the system, steam pressure is regulated using
valves and checked with steam pressure gauges.

Blowdown: Boiler blowdown is the removal of water from a boiler. Its purpose is to control boiler water
parameters within prescribed limits to minimize scale, corrosion, carryover, and other specific problems.
Blowdown is also used to remove suspended solids present in the system. These solids are caused by
feedwater contamination, by internal chemical treatment precipitates, or by exceeding the solubility
limits of otherwise soluble salts.

The fuel system includes all equipment used to provide fuel to generate the necessary heat.

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Monitoring Basic machine health data in addition to boiler operating conditions helps to maintain
reliable boiler operations. There are three areas that helps to monitor boiler performance to increase the
availability and decrease the energy costs.
o Process and condition monitoring
o Energy monitoring
o Performance and Health monitoring

Item Type
Category Equipment
Equipment Class Heater
Equipment Type Boiler

21.1 Process Performance Monitoring

The following measured parameters are monitored as it has following impact on performance and health
of the boiler if not operated in operating range.

Feed water flow: A sudden increase or decrease in Feed water flow at constant fuel firing changes
generation of steam flow which changes the pressure in the steam drum and boiler circuit. The
change in pressure will cause a change in both the boiling point and density of the water and steam.

Feed water Temperature: Improper heating of feed water results in lower boiler efficiency, incomplete
mechanical deaeration, and can cause cracking and catastrophic failure to the feedwater lines, boiler
shell, and boiler tubes through thermal shocking. Low temperatures can affect the boiler feed water

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quality as well, as it will result in higher levels of dissolved gases, oxygen and carbon dioxide, that can
corrode the internal metal surfaces the water comes in contact with. Thermal shock also occurs any time
there is a sudden change in temperature of a metal or uneven temperatures throughout the boiler. Pre-
heating the feed water to achieve an ideal boiler feed water temperature will allow the boiler to run most
efficiently as the heat input required to raise the temperature of the water up is reduced.

Fuel Flow: Fuel flow directly impact generation of steam in boiler. Higher the fuel flow in furnace
increase steam pressure and vice-versa.

Flue Temperature: Flue gas temperature measures the temperature of the combustion gases when they
leave the boiler. If the flue gas temperature is high, it suggests the heat created by the boiler isn't being
effectively used to generate steam. In other words, a high flue gas temperature suggests heat is being
lost.

Air Temperature at boiler inlet: The temperature of the combustion air entering the boiler can have a
relatively noticeable effect on industrial boiler efficiency. It can also have an impact on industrial boiler
efficiency calculations due to it affecting the net stack temperature. Net stack temperature is the
difference between the flue gas temp and the boiler inlet air temperature. Although it's tempting to
minimize ambient temperature with hopes of lowering flue gas temp, a 40-degree alteration in ambient
temperature can affect industrial boiler efficiency by one percent or more. Achieving the optimum
balance is a delicate situation that involves strategic consideration.

Steam Pressure: The pressure of generated steam directly impact generated steam temperature. To
achieve more steam temperature, pressure of steam drum need to increase to achieve desired steam
temperature.

Stack O2 %: The stack O2 content reflects the amount of excess air supplied to the burner. The
higher the excess air, the lower the boiler efficiency. The O2 analyzer allows the boiler operator to
optimize boiler fuel consumption.

Deaerator drum level: If the water in deaerator storage tank level increases then the pressure in the
deaerator increases which effects the inlet steam flow. This affects heating of inlet water which reduces
the temperature of the water. So the removal of dissolved gasses will be disturbed. The low level may not
have significance affect on the deaeration process but due to this low level the outlet flow may reduce
which is delivered to steam generator. There will be a trip signal to BFP on deaerator low level. So, the
deaerator level should be maintained.

Conductivity: Conductivity measurement is key parameter for boiler control, as it directly relates to
energy savings. Lack of conductivity monitoring leads to operational problems like scaling inside the
boiler, necessitating increased fuel consumption. Conductivity monitoring is important for minimizing
the mineral level in the boiler by replacing process water with fresh water. This removal of water is
referred to as blowdown. Conductivity monitoring also helps improve condensate recovery.

Blowdown Flow: Blowdown is an important process, excessive blowdown should be prevented to avoid
wasting water and energy. Increase in blowdown flow decreases the boiler efficiency as it contributes to
heat losses.

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Process Performance Overview: Process Performance monitoring view in UAS provides a list of the
asset attributes and their details, including the current value. This list can be used to review and update
asset attribute information, as well as to open an Asset Trend to view more details. It also highlights (in
red color) the attributes if deviates from the high or low limits.

21.2 Energy Monitoring

This Section explains the KPIs to be monitored to optimize the Energy consumption.
o Blowdown Loss: Minimizing your blowdown rate can substantially reduce energy losses, as the
temperature of the blown-down liquid is the same as that of the steam generated in the boiler.
Minimizing blowdown will also reduce makeup water and chemical treatment costs.
o Blowdown Loss (kJ/hr) = Blowdown Flow (kg/hr) *(Blowdown Enthalpy (kJ/kg)-BFW Enthalpy
(kJ/kg))
o Incomplete Combustion: Incomplete combustion can arise from a shortage of air or surplus of
fuel or poor distribution of fuel. It is usually obvious from the colour or smoke, and must be corrected
immediately. In the case of oil and gas fired systems, CO or smoke (for oil fired systems only) with
normal or high excess air indicates burner system problems. A more frequent cause of incomplete
combustion is the poor mixing of fuel and air at the burner. Poor oil fires can result from improper
viscosity, worn tips, carbonization on tips and deterioration of diffusers or spinner plates.
o Excess Air Control: Excess air is required in all practical cases to ensure complete combustion, to
allow for the normal variations in combustion and to ensure satisfactory stack conditions for some
fuels. The optimum excess air level for maximum boiler efficiency occurs when the sum of the losses

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 due to incomplete combustion and loss due to heat in flue gases is minimum. This level varies with
furnace design, type of burner, fuel and process variables. It can be determined by conducting tests
with different air fuel ratios.
o Stack Temperature: The stack temperature should be as low as possible. However, it should not be
so low that water vapor in the exhaust condenses on the stack walls. This is important in fuels
containing significant Sulphur as low temperature can lead to Sulphur dew point corrosion. Stack
temperatures greater than 200°C indicates potential for recovery of waste heat. It also indicates the
scaling of heat transfer/recovery equipment and hence the urgency of taking an early shut down for
water / flue side cleaning.

21.3 Performance Monitoring

The effective utilization of the equipment can be monitored with the help of performance indicators.

Key Performance Indicators

The following indicators help to know the overall performance of the boiler

Boiler Efficiency by direct method

Boiler Efficiency is defined as percentage of heat input that is effectively utilized to generate steam.

Energy output
η= X 100
Energy input

Q (H-h)
η= X 100
q*GCV

Where,
Q= Quantity of steam generated (kg/hr)
H= Enthalpy of steam (Kcal/kg)
h= Enthalpy of water (kcal/kg)
GCV= Gross calorific value of the fuel (kcal/kg)

q = Mass of fuel burnt (kg/hr)

Thermal Efficiency of Furnace

Thermal Efficiency is the percentage of heat available to heat process fluid with respect to heat supplied.
It accounts losses due to air and fuel preheating, air relative humidity, stack and radiation
losses. Process side heat balance is not considered in furnace efficiency calculations. Further detailed
calculations available in Furnace document under 4.1 Key performance indicator section

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 Thermal Total Heat Input - Stack Heat Loss-Radiation Heat Loss
*100
Efficiency=
Total Heat Input

(LHV+Ha+Hf) -Qs-Qr
e= *100
(LHV+Ha+Hf)

where:

e = Net thermal efficiency, %

LHV = Heat input or lower heating value of the fuel, Btu/lb of fuel

Ha = Heat input in the form of sensible heat of air, Btu/lb of fuel

Hf = Heat input in the form of sensible heat of fuel, Btu/lb of fuel

Qs = Calculated stack heat losses, Btu/lb of fuel

Qr = Assumed radiation heat loss, Btu/lb of fuel

Steam to fuel ratio

Higher steam to fuel ratio indicates good performance of the boiler and vice versa.

Steam to fuel ratio= Steam Flow(kg/hr)/Fuel Flow(kg/hr)

Air to Fuel Ratio

It is measures in range and this range varies with fuel type. High Air to fuel ratio contributes to heat
losses and low Air to fuel ratio contributes to incomplete combustion.

Air to Fuel Ratio = Air Flow(kg/hr)/Fuel Flow(kg/hr)

Water Balance
Water balance show the quantity of water flow in and out of system with steam generation.

Water Balance =(BFW_Flow-Steam_Flow-BlowdownRate)

Performance Overview

Equipment Key Performance Indicators (KPIs) view in UAS provides a list of KPIs and their details,
including the current value. This list can be used to review and update asset attribute information, as
well as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if
deviates from the high or low limits.

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21.4 Failure Modes
In Uniformance Asset Sentinel, you can configure faults, symptoms, and fault models on boiler
performance output to diagnose the problems early. The fault management can inform operators of any
violations of the nominal boiler operating range and deviations from the expected characteristic and
make this data available for further processing through the historian. The fault symptoms or models are
used to:
o Warn against potential damage to boiler under unfavorable operating conditions.
o Provide early warning of damages to the boiler.

The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions
o Steam to Fuel Ratio Low: It indicates lower steam generation for higher fuel consumption. This
can happen due to low BFW temperature or heat losses from flue gases released at stack.
o Flue Gas Exit Temp High: It indicates heat losses to flue gas which result in lower boiler efficiency.
It causes due to excess air flow.
o Boiler Efficiency Low: It indicates lower steam generation at higher energy input.
o Thermal Efficiency Low: It indicate supplied energy in form of fuel is not fully utilized to generate
steam.
o Air to Fuel Ratio low: Lower air to fuel ratio indicates incomplete combustion of fuel.
o NOx Emission High: It indicate higher concentration of nitrogenous compound in fuel gas. This
indication can also help to monitor environmental norms and limit NOx emission.
o CO Emission High: Higher CO Emission indicate incomplete combustion of fuel result in lower
boiler efficiency.
o Boiler drum level low: Sudden increaser or decrease in boiler drum impact generation of steam
flow which Impact pressure of steam drum. This can be happened due to fluctuation in BFW flow.
o Steam Drum Priming: It causes due to sudden change in boiler load or high level in steam drum. It
can nullify by decreasing boiler load.
o Steam Drum Foaming: It causes when Boiler feed water contaminated with oil. It can nullify by
removing contaminated water vie blowdown.
o Carry over from steam drum: It impact quality of steam generated, it causes due to sudden
change in boiler load.

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 o Steam Drum Abnormal Level Sudden increase or decrease in steam drum level affect pressure of
steam drum.
o Abnormal Combustion: Abnormal combustion impact heat input to BFW which Impact generation
of steam.
o Deaerator Level Low: Low water level in deaerator drum decreased the pressure in the
deaerator drum which effects the inlet steam flow. This affects heating of inlet water which
increases the temperature of the water.
o Dissolved Oxygen High: Dissolved oxygen is the major cause of boiler corrosion and carbon
dioxide makes the water acidic which harm boiler.

Below table illustrates the list of faults and symptoms configured for a boiler to identify possible
anomalies that affects the performance or health of a boiler.

Fault Category Fault Name Associated Symptoms

Blowdown Losses High

Energy Energy Consumption High
Steam Temperature High
Steam Drum Level Low
Energy Steam Drum Instability
Water Balance High
Conductivity Low
Health Health Degradation Warning
Dissolved Oxygen High
Boiler Efficiency Low
Steam to Fuel Ratio Low
Performance Performance Degradation Warning
Potential Water CarryOver
Steam Drum Pressure Low

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

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21.5 Configuration
As described in previous sections, boiler performance monitoring model is used to:
o Calculate the current operating point data such as head, power consumed, and NPSH. The
calculation is performed based on the inputs received from DCS/Historian or based on the
configured model parameters.
o Interpolate or extrapolate the design data for the current operating FlowRate from the
Manufacturer performance curve.

The calculation model to perform as expected, it requires some inputs are to be feed into the model. The
boiler model input data consists of measured data and static data. Measured input data is supplied to
the model from DCS or Historian by tag mapping. This section describes the list of input and output
attributes and its properties.

Model Input data

S Attribute Monitoring
Attribute Description Units Source
No Category Category

1 Air Flow Rate Air Flow Rate (Input) kg/hr Dynamic Process Field Input
Air Inlet Air Inlet Temperature
2 Temperature (Input) deg C Dynamic Process Field Input
3 BFW Flow Rate BFW Flow Rate (Input) kg/hr Dynamic Process Field Input
4 BFW Pressure BFW Pressure (Input) barg Measured Process Field Input

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 BFW Temperature
5 BFW Temperature (Input) deg C Calculated Process Field Input
Asset Connection BFW
6 BFW Stream_In Stream Inputs Static Connection
7 Blowdown Rate Blowdown Rate (Input) kg/hr Dynamic Process Field Input
Asset Connection
Blowdown Stream
8 BlowdownStream_In Inputs Static Connection
Boiler Drum Level
9 Boiler Drum Level (Input) % Dynamic Process Field Input
Asset Connection
10 Combustor_In Combustor Inputs Static Connection
11 Conductivity Conductivity (Input) Dynamic Process Field Input
Deaerator Drum Deaerator Drum Level
12 Level (Input) % Dynamic Process Field Input
Dissolved Oxygen
13 Dissolved Oxygen (Input) Dynamic Process Field Input
Enthalpy of Feed Enthalpy of Feed
14 water water(Input) kJ/kg Dynamic Process Field Input
15 Flue Gas Temp Flue Gas Temp (Input) deg C Dynamic Process Field Input
16 Fuel Flow Rate Fuel Flow Rate (Input) kg/hr Dynamic Process Field Input
Furnace Pressure(
17 Furnace Pressure Input) barg Dynamic Process Field Input
Mole
18 Stack Oxygen Stack Oxygen (Input) Fraction Dynamic Process Field Input
Enthalpy of
19 Enthalpy of Steam Steam(Input) kJ/kg Dynamic Process Field Input
20 Steam Flow Steam Flow(Input) kg/hr Dynamic Process Field Input
21 Steam Pressure Steam Pressure (Input) barg Dynamic Process Field Input
Steam Temperature
22 Steam Temperature (Input) deg C Dynamic Process Field Input
Asset Connection Steam
23 Steam Stream_In Stream Inputs Static Connection
Asset Connection
24 UAnalyzer_In Ultimate Analyzer Inputs Static Connection
Fuel Calorific Value Internally
25 Fuel Calorific Value (Input) kJ/kg Dynamic Internal calculated
Internally
26 Fuel Moisture Fuel Moisture (Input) % Calculated Internal calculated
Internally
27 Fuel Pressure Fuel Pressure (Input) barg Dynamic Internal calculated
Asset Connection
28 FuelStream_In FuelStream Inputs Static Internal Constant
29 Enthalpy at Enthalpy at saturated kJ/kg Dynamic Internal Internally

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 saturated Pressure Pressure(Input) calculated

Model Output data

S Attribute Monitoring
Attribute Description Units Source
No Category Category

1 Air to Fuel Ratio Air to Fuel Ratio (Output) Dynamic Performance Calculated
2 BlowDown Loss Blow Down Loss (Output) kJ/hr Dynamic Energy Calculated
3 Boiler Efficiency Boiler Efficiency (Output) % Dynamic Performance Calculated
Steam to Fuel Steam to Fuel Ratio
4 Ratio (Output) Dynamic Performance Calculated
Thermal Thermal Efficiency Indirect
5 Efficiency Method (Output) % Dynamic Performance Calculated
6 Water Balance Water Balance(Output) kg/hr Dynamic Performance Calculated

Configuring a Boiler Asset in Uniformance Asset Sentinel

To configure a boiler asset

Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter
Steam_Boiler_SB01.

Refer to the following procedures:

o To configure asset connection attributes.
o To map a dynamic attribute to the datasource tags.
o To set the attribute properties for the Attribute Viewer and Performance Overview.
o To manually update asset attribute information.

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 HRSG Monitoring

A heat recovery steam generator (HRSG) is one of the major pieces of equipment in a gas turbine
combined cycle power plant that boasts a high thermal efficiency and produces minimal
CO2 emissions. An HRSG is a kind of heat exchanger that recovers heat from the exhaust gases of a
gas turbine to an extreme degree. The heat is recovered in the form of steam which is served as the
power source of a power-generating steam turbine.

For the heat-transfer tubes of an HRSG, finned tubes with excellent heat-transfer performance are
employed. By adopting a compact design, the installation footprint of the equipment is reduced.

HRSGs consist economizer, evaporator and superheater . The different components are put
together to meet the operating requirements of the unit.

Economiser: The first major HRSG circuit component is the economizer. An economizers function is to
increase water temperature to an "approach" temperature near the saturation temperature. Approach
temperature is carefully chosen to ensure maximum heat energy absorption efficiency and operational
flexibility.

Evaporator: Evaporator sections are where the boiling process or steam generation occurs. As heat
energy is absorbed by water from the gas stream, the water temperature increases. When water reaches
the boiling point or saturation temperature, some of the water evaporates or vaporizes to steam.

Superheater: The last major component of a steam generator circuit is the Superheater. The major
function of a Superheater is to increase steam temperature above saturation. High steam temperature
minimizes the introduction of water as liquid to the steam turbine and improves steam cycle efficiency.
The Superheater absorbs heat energy from the CT exhaust gas and transfers this energy to the steam.
The steam superheat energy level is measured as an increase in steam temperature beyond the steam
temperature achieved in the evaporator section. The Superheater sections typically have the highest
metal temperatures in the HRSG. Superheater sections are composed of extended or finned tube
surface modules. The high-pressure Superheater modules are one-pass, two-row modules and are
arranged in a series/parallel configuration to reach the desired final steam temperature and capacity.

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Monitoring Basic machine health data in addition to HRSG operating conditions helps to maintain
reliable boiler operations. There are three areas that helps to monitor HRSG performance to increase the
availability and decrease the energy costs.
o Process and condition monitoring
o Energy monitoring
o Performance and Health monitoring

Item Type
Category Equipment
Equipment Class HRSG
Equipment Type AS_HRSG

22.1 Process Performance Monitoring

The following measured parameters are monitored as it has following impact on performance and health
of the boiler if not operated in operating range.

BlowDown Flow Rate: Blowdown is used to reduced dissolved solids, ph, conductivity and silica contain
of HRSG water. Reducing blowdown rate can substantially reduce energy losses, as the temperature of
the blown-down liquid is the same as that of the steam generated in the boiler. Minimizing blowdown will
also reduce makeup water and chemical treatment costs. Insufficient blowdown may lead to carryover of
boiler water into the steam, or the formation of deposits. Excessive blowdown will waste energy, water,
and chemicals.

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Conductivity: It is important monitoring parameter for HRSG since its used for detecting impurity in
leakage. If a condenser tube fails or impurities enter from another source like makeup water the sodium,
calcium, and magnesium salts in the water are converted to their respective acids, primarily dilute
sulfuric and hydrochloric acids, by the cation exchange column. The dilute acids that emerge (HCl and
H2SO4, primarily) are more conductive than their respective salts and have an immediate influence on
conductivity, thus providing a quick indication of upsets. In general, the cation conductivity of a clean
condensate sample should be less than 0.2 micromhos (microsiemens) per centimeter (µS). This limit is
mandatory to monitor to minimize corrosion in economizers and evaporator tubes.

Deaerator Drum Level & Dissolved Oxygen: The deaerator drum should maintain dissolved oxygen
concentrations below 10 ppb. Deaerator outlet sampling for dissolved oxygen (grab sampling is most
common) helps the plant operator or chemist monitor deaerator performance. An increase in dissolved
oxygen levels over normal concentrations could indicate problems with the internal deaerator
components. Trays may become misaligned. Or, the deaerator vents may not be adjusted properly.

Steam Drum Level: The steam drums are steam/water separators, storage tanks, and water treatment
sites for steam purity control. Drum boilers operate in the area on the saturation curve. The steam/water
mixture entering the drum from the riser tubes usually is 5-10% steam depending on the boiler load and
pressure. Staying at low-quality levels protects the tubes from overheat failures due to the nature of the
boiling process. In the steam drum, saturated steam is separated from the steam/water mixture.

Feed Water Mass Flow Rate: Feed water flow influence generation of steam however quality of feed
water also plays important role on generated steam quality. Excessive feedwater contamination will
reduce the boiler cycles of concentration and require increased blowdown.

HRSG Inlet Temperature: Inlet temperature of HRSG directly impact generated steam temperature,
higher inlet temperature of HRSG produce high temperature of steam and increase efficiency of HRSG.

Flue Gas Volume Flow Rate: It indicate load to HRSG, higher flue gas flowrate higher load to HRSG and
produce high steam rate.

Auxiliary Fuel flowrate: Auxiliary fuel is used to utilized oxygen in turbine exhaust gases that can be
utilized to fire additional fuel to the exhaust gas and thus increase its temperature. Increase in inlet gas
temperature generates additional steam in the evaporator, which increases the capacity of the heat sink,
which is the economizer. The auxiliary fuel firing is an excellent way of generating additional steam in
HRSGs and fuel utilization is nearly 100% or even more. That is, one can generate additional steam with
nearly the same amount or lesser amount of fuel.

Process Performance Overview: Process Performance monitoring view in UAS provides a list of the
asset attributes and their details, including the current value. This list can be used to review and update
asset attribute information, as well as to open an Asset Trend to view more details. It also highlights (in
red color) the attributes if deviates from the high or low limits

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22.2 Energy Monitoring
This Section explains the KPIs to be monitored to optimize the Energy consumption.

Blowdown Loss: Minimizing your blowdown rate can substantially reduce energy.

22.3 Performance Monitoring

The effective utilization of the equipment can be monitored with the help of performance indicators.

Key Performance Indicators

The following indicators help to know the overall performance of the HRSG

HRSG Efficiency
It is expressed as heat generated inform of steam by heat input as fuel. This efficiency can be evaluated
using the formula

HRSG Efficiency = Heat Output /Heat Input × 100

HRSG Efficiency = Qx (hg−hf ) /q×GVC × 100

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 Where,

Q= Quantity of steam generated per hour in kg/hr

q = Quantity of fuel used per hour in kg/hr

hg – Enthalpy of saturated steam in kCal/kg of steam

hf – Enthalpy of feed water in kCal/kg of wate

GVC- gross calorific value of the fuel in kCal/kg of fuel

CoGeneration Efficiency
The cogeneration efficiency is explained, as power generated by gas turbine calculations using steam
generation to heat provided to HRSG and it is expressed as,

CoGeneration Efficiency= Power output + HRSG output

Gas turbine fuel input*LHV of Fuel

Steam to Fuel Ratio

It is ratio of steam flow to fuel flow to HRSG.Higher steam to fuel ratio indicates good performance of the
boiler and vice versa.

Steam to fuel ratio= Steam Flow(kg/hr)/Fuel Flow(kg/hr)

Water Balance
Water balance show the quantity of water flow in and out of system with steam generation.

Water Balance = (BFW_Flow-Steam_Flow-BlowdownRate)

Performance Overview
Equipment Key Performance Indicators (KPIs) view in UAS provides a list of KPIs and their details,
including the current value. This list can be used to review and update asset attribute information, as
well as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if
deviates from the high or low limits.

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22.4 Failure Modes
In Uniformance Asset Sentinel, you can configure faults, symptoms, and fault models on HRSG
performance output to diagnose the problems early. The fault management can inform operators of any
violations of the nominal HRSG operating range and deviations from the expected characteristic and
make this data available for further processing through the historian. The fault symptoms or models are
used to:
o Warn against potential damage to HRSG under unfavorable operating conditions.
o Provide early warning of damages to the HRSG.

The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions
o Steam to Fuel Ratio Low: It indicates lower steam generation for higher fuel consumption. This
can happen due to low BFW temperature or heat losses from flue gases released at stack.

Below table illustrates the list of faults and symptoms configured for a HRSG to identify possible
anomalies that affects the performance or health of a HRSG.

Fault Category Fault Name Associated Symptoms

HRSG Efficiency Low

Co-Gen Efficiency Low
Steam to Fuel Ratio Low
Performance HRSG Performance Low
Supplementary Firing Stopped
Potential Water Carry Over in Steam
Steam Drum Pressure Low
Conductivity Low
Health Health Degradation Warning
Dissolved Oxygen High
Steam Drum Level Low
Energy Steam Drum Instability
Water Balance High
Blowdown Losses High
Energy Energy Consumption High Steam Temperature High
HRSG Outlet Temp High

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

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22.5 Configuration
As described in previous sections, HRSG performance monitoring model is used to:
o Calculate the current operating point data such as head, power consumed, and NPSH. The
calculation is performed based on the inputs received from DCS/Historian or based on the
configured model parameters.
o Interpolate or extrapolate the design data for the current operating FlowRate from the
Manufacturer performance curve.

The calculation model to perform as expected, it requires some inputs are to be feed into the model. The
boiler model input data consists of measured data and static data. Measured input data is supplied to
the model from DCS or Historian by tag mapping. This section describes the list of input and output
attributes and its properties.

Model Input data

S Attribute Monitoring
Attribute Description Units Source
No Category Category

BlowDown Flow BlowDown Flow Rate Field

1 Rate (Input) kg/hr Dynamic Process Input
Field
2 Conductivity Conductivity (Input) Dynamic Process Input

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 Deaerator Drum Deaerator Drum Level Field
3 Level (Input) % Dynamic Process Input
Dissolved Dissolved Oxygen Field
4 Oxygen (Input) Dynamic Process Input
Steam Drum Steam Drum Level Field
5 Level (Input) % Dynamic Process Input
Feed Water Feed Water Mass Flow Field
6 Mass Flow Rate Rate (Input) kg/hr Dynamic Process Input
Feed Water Feed Water Pressure Field
7 Pressure (Input) barg Dynamic Process Input
Feed Water Feed Water Temperature Field
8 Temperature (Input) deg C Dynamic Process Input
Flue Gas Mass Flue Gas Mass Flow Field
9 Flow Rate Rate (Input) kg/hr Dynamic Process Input
HRSG Inlet Flue Gas Inlet Field
10 Temperature Temperature (Output) deg C Dynamic Process Input
HRSG Outlet Flue Gas Outlet Field
11 Temperature Temperature (Output) deg C Dynamic Process Input
Flue Gas Volume Flue Gas Volume Flow Field
12 Flow Rate Rate (Input) m3/hr Calculated Process Input
HRSG Fuel Mass HRSG Fuel Mass Flow Field
13 Flow Rate Rate (Input) kg/hr Dynamic Process Input
Auxiliary Fuel Auxiliary Fuel Pressure Field
14 Pressure (Input) barg Dynamic Process Input
Auxiliary Fuel Auxiliary Fuel Field
15 Temperature Temperature (Input) deg C Dynamic Process Input
GT Fuel Mass GT Fuel Mass Flow Rate Field
16 Flow Rate (Input) kg/hr Dynamic Process Input
Field
17 GT Power in MW GT Power in MW (Input) megawatts Dynamic Process Input
Steam Mass Steam Mass Flow Rate Field
18 Flow Rate (Input) kg/hr Dynamic Process Input
Field
19 Steam Pressure Steam Pressure (Input) barg Dynamic Process Input
Steam Steam Temperature Field
20 Temperature (Input) deg C Dynamic Process Input
Steam Drum Steam Drum Pressure Field
21 Pressure (Input) barg Dynamic Process Input

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Model Output data

S Attribute Monitoring
Attribute Description Units Source
No Category Category

BlowDown Loss
1 BlowDown Loss (Output) kJ/hr Dynamic Internal Calculated
CoGeneration CoGeneration Efficiency
2 Efficiency (Output) % Dynamic Performance Calculated
Feed Water Feed Water Enthalpy
3 Enthalpy (Input) kJ/kg Dynamic Internal Calculated
Flue Gas Flue Gas Specific Heat
4 Specific Heat (Input) kJ/kg-C Dynamic Internal Calculated
Fuel Calorific Fuel Calorific Value
5 Value (Input) kJ/kg Dynamic Internal Calculated
6 GT Total Power GT Total Power (Input) kJ/hr Dynamic Internal Calculated
HRSG Efficiency
7 HRSG Efficiency (Output) % Dynamic Performance Calculated
8 Steam Enthalpy Steam Enthalpy (Input) kJ/kg Dynamic Internal Calculated
Steam to Fuel Steam to Fuel Ratio
9 Ratio (Output) Dynamic Performance Calculated
10 Water Balance Water Balance (Output) kg/hr Dynamic Performance Calculated

Configuring a HRSG Asset in Uniformance Asset Sentinel

To configure a HRSG asset with performance model

Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter
AS_HRSG to configure HRSG.

Refer to the following procedures:

o To configure asset connection attributes.
o To map a dynamic attribute to the datasource tags.
o To set the attribute properties for the Attribute Viewer and Performance Overview.

To manually update asset attribute information.

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 Plate and Frame Heat
Exchanger

A Plate heat exchanger uses metal plates to transfer heat between two fluids. This has a major advantage
over a conventional heat exchanger in that the fluids are exposed to a much larger surface area because
the fluids are spread out over the plates. This facilitates the transfer of heat, and greatly increases the
speed of the temperature change.

A plate exchanger consists of a series of parallel plates that are placed one above the other so as to allow
the formation of a series of channels for fluids to flow between them. The space between two adjacent
plates forms the channel in which the fluid flows. Inlet and outlet holes at the corners of the plates allow
hot and cold fluids through alternating channels in the exchanger so that a plate is always in contact on
one side with the hot fluid and the other with the cold.

All plate heat exchangers look similar on the outside. The difference lies on the inside, in the details of
the plate design and the sealing technologies used. Hence, when evaluating a plate heat exchanger, it is
very important not only to explore the details of the product being supplied but also to analyze the level
of research and development carried out by the manufacturer and the post-commissioning service and
spare parts availability.

An important aspect to take into account when evaluating a heat exchanger are the forms of corrugation
within the heat exchanger. There are two types: intermating and chevron corrugations. In general, greater
heat transfer enhancement is produced from chevrons for a given increase in pressure drop and are
more commonly used than intermating corrugations.

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This document explains Plate and Frame Heat Exchanger monitoring philosophy for process,
performance, energy and health parameters and their importance.

Item Type
Category Equipment
Equipment Class Heat Exchanger
Equipment Type Plate and Frame

23.1 Process Performance Monitoring

The following measured parameters are monitored as it has following impact on performance and health
of the Plate and Frame heat exchanger if not operated in operating range.

Inlet Temperature: The increase or decrease of the inlet temperature will affect the heat transfer within
the heat exchanger and thereby varies the outlet temperature.

Volumetric flow rate: The increase in the flow rate of fluids results in increase in the film heat transfer
coefficient and thereby increase in the expected overall heat transfer coefficient.

Inlet Pressure: The increase or decrease in pressure can vary parameters like temperature, velocity of
flow etc., which ultimately may affect convective heat transfer coefficient.

Duty: It is direct measurement of heat exchanged in that heat exchanger.

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LMTD: The LMTD is a logarithmic temperature difference of the fluids at both the sides of the heat
exchangers. It’s used to determine the temperature driving force for heat transfer in flow systems, most
notably in heat exchangers. For a given heat exchanger with constant area and heat transfer coefficient,
the larger the LMTD, the more heat is transferred.

Process Performance Overview: Process Performance monitoring view in UAS provides a list of the
asset attributes and their details, including the current value. This list can be used to review and update
asset attribute information, as well as to open an Asset Trend to view more details. It also highlights (in
red color) the attributes if deviates from the high or low limits.

23.2 Performance Monitoring

The effective utilization of the equipment can be monitored with the help of performance indicators.

Key Performance Indicators

The following indicators help to know the overall performance of the Plate and Frame Heat Exchanger

Hot side Duty

Hot side duty calculated as

Hot Side Duty Qh = Mc*CpH* ΔTh

Where, Mc = Mass flow rate of hot fluid.

CpH = Specific heat of hot fluid.

ΔTh = Hot fluid temperature difference

Cold side Duty

Cold side duty calculated as

Cold Side Duty Qc = Mc*CpC* ΔTc

Where, Mc = Mass flow rate of cold fluid.

CpC = Specific heat of cold fluid.

ΔTc = Cold fluid temperature difference.

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Operating Duty
The amount of energy transferred from one fluid to another within the exchanger, it is calculated using,
mass flow, temperature change of both hot and cold fluid and effective surface area. It is average of the
hot and cold fluid Duty.

Operating Duty Q = Average (Hot fluid Duty and Cold Fluid Duty)

Operating Heat transfer coefficient

Heat transfer coefficient is a quantitative characteristic of convective heat transfer between a fluid
medium (a fluid) and the surface (wall) flowed over by the fluid.

Operating Heat transfer coefficient is calculated at current operating conditions as follows.

Operating HTC= Overall Duty/ (Design Heat Transfer Area*Operating LMTD)

Where, Operating LMTD = ΔTTM * FT

Log mean temperature difference ΔTTM = (T1-t2) – (T2-t1)

Ln((T1-t2) / (T2-t1))

Where, T1 = inlet temperature of the hot fluid

T2= exit temperature of the hot fluid

t1 = inlet temperature of the cold fluid

t2 = exit temperature of the cold fluid

LMTD correction factor FT = ((SQRT(R^2+1)/(R-1)) *LN((1-x)/(1-R*x)))/LN((2/x-1-

R+SQRT(R^2+1))/(2/x-1-R-SQRT(R^2+1)))

R = (T1-T2) – (t2-t1)

P = (t2-t1) – (T1-t1)

X = (1 - ((R*P-1)/(P-1)) ^(1/N))/ (R - ((R*P-1)/(P-1)) ^(1/N))

Where, N = Number of Shell side passes

Performance Overview
Equipment Key Performance Indicators (KPIs) view in UAS provides a list of KPIs and their details,
including the current value. This list can be used to review and update asset attribute information, as
well as to open an Asset Trend to view more details. It also highlights (in red color) the attributes if
deviates from the high or low limits.

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23.3 Failure Modes
In Uniformance Asset Sentinel, faults, symptoms, and fault models are configured based on Heat
Exchanger performance model outputs and process Parameters measured from field to diagnose the
problems early. The fault management can inform operators of any violations of the nominal Heat
Exchanger operating range and deviations from the expected characteristic and make this data
available for further processing through the historian. The fault symptoms or models are used to:
o Warn against potential damage to Heat Exchanger under unfavorable operating conditions.
o Provide early warning of damages to the Heat Exchanger.

The following messages can be generated for process alarms or notifications to warn operating
personnel of unfavorable operating conditions:
o Heat transfer degradation: occurs mainly due to fouling and leakage in heat exchanger.
o Low effectiveness: occurs due to variation in temperatures at inlet and outlet. It can be avoided by
operating the heat exchanger at optimal conditions.
o Leakage: It can be detected by checking the material balance.
o Possible damage to pipes: The most probable cause is debris in the fuel nozzles. This results in
very less combustor efficiency and less turbine inlet temperature.
o Fouling: It is an important factor in heat exchangers, caused due to deposition of material on the
Heat transfer surfaces. The heat exchanger effective heat duty and heat transfer coefficient
decreases when fouling occurs. Fouling predictions are used to predict the maintenance schedules
for cleaning heat exchanger.

Below table illustrates the list of faults and symptoms configured for a Plate and Frame Heat Exchanger.
Fault
Fault Name Associated Symptoms
Category
Cold Side Outlet Temperature Low
Performance Low Hot Side Outlet Temperature High
Performance
Warning Operating Duty Low
Operating HTC Low
Health PHE Fouling Warning Cold Side Pressure Drop High

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 Fault
Fault Name Associated Symptoms
Category
Fouling Percentage High
Hot Side Pressure Drop High

The Fault Tree provides graphical display of assets and associated faults and symptoms. The Fault Tree
is used to locate the source of a fault in single view. Hence, analyzing the fault easier with navigation
views.

23.4 Configuration
The purpose of the plate and frame heat exchanger model is to determine the operating, design, and
deviation performance. The operating performance of a heat exchanger is determined using measured
input data supplied to the condition analysis program through the site instrumentation and historian.
The operating performance is calculated for each set of measured input data. In addition to the
measured input data, a number of model parameters must also be supplied by the user through the user
interface.

Model Input data

Attribute Monitoring
S No Attribute Description Units Source
Category Category

Cold Side Cold Side Fluid Density ThermoPro

1 Fluid Density (Input) kg/m3 Dynamic perty Field Input

Cold Side Inlet Cold Side Inlet

2 Temperature Temperature (Input) deg C Dynamic Process Field Input
Cold Side Cold Side Outlet
3 Outlet Temperature (Input) deg C Dynamic Process Field Input

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 Attribute Monitoring
S No Attribute Description Units Source
Category Category
Temperature

Cold Side
Volume Flow Cold Side Volume Flow
4 Rate Rate (Input) m3/hr Dynamic Process Field Input

Cold Side Inlet Cold Side Inlet

5 Pressure Pressure (Input) barg Dynamic Process Field Input

Cold Side
Outlet Cold Side Outlet
6 Pressure Pressure (Input) barg Dynamic Process Field Input
kilocal
ories/k
ilogra
m_deg
Cold Side Cold Side Specific ree_Cel ThermoPro
7 Specific Heat Heat (Input) sius Dynamic perty Field Input
kilocal
ories/k
ilogra
m_deg
Hot Side Hot Side Specific Heat ree_Cel ThermoPro
8 Specific Heat (Input) sius Dynamic perty Field Input

Clean Overall Heat

Transfer Coefficient
9 HTC Clean (Input) Static Design Constant
Hot Side Fluid Hot Side Fluid Density ThermoPro Field Input
10 Density (Input) kg/m3 Dynamic perty
Hot Side Inlet Hot Side Inlet Field Input
11 Temperature Temperature (Input) deg C Dynamic Process
Field Input
Hot Side
Outlet Hot Side Outlet
12 Temperature Temperature (Input) deg C Dynamic Process
Hot Side Field Input
Volume Flow Hot Side Volume Flow
13 Rate Rate (Input) m3/hr Dynamic Process
Hot Side Inlet Hot Side Inlet Pressure Field Input
14 Pressure (Input) barg Dynamic Process
Hot Side Field Input
Outlet Hot Side Outlet
15 Pressure Pressure (Input) barg Dynamic Process

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 Attribute Monitoring
S No Attribute Description Units Source
Category Category

LMTD_Correct LMTD Correction

16 ion_F Factor (Input) Static Design Constant
Overall Heat Overall Heat Transfer
17 Transfer Area Area (Input) m2 Static Design Constant

Model Output data

Attribute Monitoring
S No Attribute Description Units Source
Category Category

1 Approach Approach (Output) deg C Dynamic Performance Calculated

Cold Side Cold Side Heat Duty

2 Heat Duty (Output) kilocalories/hour Dynamic Performance Calculated

Cold Side
Pressure Cold Side Pressure
3 Drop Drop (Output) bar Dynamic Performance Calculated

Fouling Fouling Percentage

4 Percentage (Output) % Dynamic Performance Calculated
Fouling Fouling Factor
5 Factor (Output) Dynamic Performance Calculated
Hot Side Hot Side Heat Duty
6 Heat Duty (Output) kilocalories/hour Dynamic Performance Calculated

Hot Side Hot Side Pressure

7 PressureDrop Drop (Output) bar Dynamic Performance Calculated
Operating Heat Transfer
8 HTC Coefficient (Output) Dynamic Performance Calculated

Ratio of Hot side

duty to Cold side
9 Intensity duty (Output) Dynamic Performance Calculated

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 Attribute Monitoring
S No Attribute Description Units Source
Category Category

10 LMTD LMTD (Output) deg C Dynamic Performance Calculated

Cold Fluid
Mass Flow Cold Fluid Mass
11 Rate Flow Rate (Output) kg/hr Dynamic Process Calculated
Hot Fluid
Mass Flow Hot Fluid Mass Flow
12 Rate Rate (Output) kg/hr Dynamic Process Calculated
Overall Heat Duty
13 Overall Duty (Output) kilocalories/hour Dynamic Performance Calculated

Configuring a Plate and Frame Heat Exchanger Asset in

Uniformance Asset Sentinel
To configure a Plate and Frame Heat Exchanger asset with performance model

Follow the sequence of steps provided in “Configuring Assets” in the Uniformance Asset Sentinel
Configuration Guide to configure an asset in Uniformance Asset Sentinel. In the Type box, enter Plate
and Frame HE.

Refer to the following procedures:

o To configure asset connection attributes.
o To map a dynamic attribute to the datasource tags.
o To set the attribute properties for the Attribute Viewer and Performance Overview.
o To manually update asset attribute information.

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 Asset Management Metrics

There is a predefined metrics asset type template. It allows capturing of various state parameters like
availability, running duration, faulted state, and so on, for an asset. Details of predefined Metrics states
are captured in the chapter “Configuring Asset Metrics” in the Uniformance Asset Sentinel Configuration
Guide.

These metrics are templatized under asset type named “Equipment Metrics Template” in standard
library content. Once the metrics related template is imported, the model associated to the template can
be linked to any other asset. Details captured in the section “Adding Calculations from Other Assets or
Types” in the Uniformance Asset Sentinel Configuration Guide.

The following metrics-related attributes are created under asset type templates. It can be then linked to
metrics calculation model at the asset level.
o AssetIndex
o Availability
o FaultedDuration
o MaintenanceDuration
o Performance
o RunningCycles
o RunningDurationTotal

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 UniSim Design (USD)
Integration

The key performance parameters of assets that are modeled using USD can be calculated and the
results of calculation sent back to Uniformance Asset Sentinel. The input variables and output variables
of these assets must be configured in USD and mapped to the relevant tags in Uniformance Asset
Sentinel (see “UniSim Design Integration” in the Uniformance Asset Sentinel Configuration Guide).

The plant data is pre-processed and initialize UniSim model. The results from UniSim are historized and
analyzed for faults.

NOTE
Models that are in “Steady” state can only be used for analysis in USD.

USD data sources in Uniformance Asset Sentinel are configured to execute modeling in two different
modes:
o Simulation Calculation: the calculation of equipment/process performance using the configured
UniSim design model.
o Optimization: identifying the optimal process condition or reconcile measurements, equipment
parameters using the configured UniSim design model.

25.1 USD Snapshots

When a USD model executes, a snapshot file is saved to the location configured on the USD data source
(see “Configure a UniSim Design (USD) Data source” in the Uniformance Asset Sentinel Configuration Guide).
Depending on the execution result, the snapshot will either be saved to the Success or Fail folders within
the folder location.

If the model needs to be adjusted (either the change the calculations of KPIs, or to address errors), the
snapshot files can be loaded in UniSim Design, when the model can be reviewed and re-tuned.

Once the model has been adjusted in UniSim Design, a new case file can be exported, and loaded into
the USD data source.

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25.2 USD Parameters
The following parameters are used with the Uniformance Asset Sentinel UniSim Interface, and the
UniSim Optimization Status.

Uniformance Asset Sentinel-UniSim Interface Parameters

o Execution Mode: The current mode of the Sentinel interface to UniSim. The Execution Mode
changes while the UniSim model is loaded, running, completed, and so on.
o Execution Flag: The UniSim calculation model can be scheduled based on the interval configured
or executed whenever this particular attribute value changes to one. The Sentinel Engine resets the
value to zero once it recognize the request to execute, so that subsequent triggering can happen to
re-execute the UniSim model.
o Error Status: The status of the last UniSim model execution.
o Remaining Time: The UniSim calculation is configured with a time out. Whenever the execution
starts, the remaining time is set to timeout and decreases until the execution is completed.

UniSim Optimization Status Parameters

o Phase: Displays the current phase of the Optimizer algorithm. Values include Initialize, Setup, OPT
Deriv, OPT Search, and Results.
o Evaluation Count: Reports the number of model evaluations performed during the course of the
optimization.
o FP Iterations: Displays the number of minor iterations since the last major iteration.
o Gradient Iterations: Reports the number of gradient evaluations performed during the course of
the optimization.

25.3 Simulator Interface

Asset Sentinel interface with UniSim Design to perform KPI calculation by running simulator in
calculation mode.

Execution Mode
The following are the possible values for the execution mode attribute in UniSim Interface asset.
o CALCULATION Run In Progress = 9
o CALCULATION Run returned SUCCESS = 12
o CALCULATION Run ERROR or not converged= 11
o CALCULATION Run Timedout = 10

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Error Status
The follow are the possible values for the Error Status attribute in UniSim Interface asset.
o Not Converged =13
o Success =1
o Timed out = 20

25.4 Optimizer Interface

NOTE
Refer to Section 7: Derivative Utility & Optimizer in the RTO Reference Guide for how to setup optimizer
in UniSim Design. This document should be available in your UniSim Design installation folder.

In Asset Sentinel configure the USD interface with execution mode as optimizer to execute optimizer and
generate snapshots periodically with plant preprocess data.

Execution Mode
The following are the possible values for the execution mode attribute in UniSim Interface asset:
o OPTIMIZATION Run In Progress = 14
o OPTIMIZATION Run returned SUCCESS = 17
o OPTIMIZATION Run returned ERROR = 16
o OPTIMIZATION Run Timedout = 15

Error Status
The following tables show the possible values for the Error Status attribute for each type of optimizer.

NOVA Optimization Description Success

Error Code

0 Successful solution Yes

1 Infeasible problem Yes
-2 Unbounded solution Yes
2 Running NA
3 Not Run No
-3 Bounds crossed for some constraint No

-4 Invalid input No

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-5 User model abort command received No

-6 Insufficient work space for nlp No

-7 Insufficient work space for reduced No
Hessian
-8 Insufficient work space for LU No
factors
-9 Maximum iterations No
-10 Bad derivative information No
-11 Too much accuracy requested No
-12 External abort command received No
-13 System error No

Legacy SQP Description Success

Optimization Error
Code

1 Success Yes
4 Step convergence Yes
5 Cost convergence Yes
7 Gradient convergence Yes
11 Timeout feasible Yes
13 Not converged Yes
16 Relaxed OK Yes
18 Cost convergence - at feasible point limit Yes
2 Impossible No
8 Globally infeasible No
9 Infeasible No
6 Flat convergence No
10 Unbounded No
12 Timeout infeasible No
14 Not Run No
3 No variables No
15 Stopped No

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 Appendix: APR Templates

26.1 Introduction
Honeywell is working in partnership with Expert Microsystems to provide an Advanced Pattern
Recognition (APR) analytics capability, integrated with the Uniformance Asset Sentinel solution. This
approach complements the standard first principles asset templates, providing early detection of
equipment and instrumentation issues and extending the capability of UAS to monitor equipment types
and sub-systems not covered today by the standard models.

The capability leverages the SureSense® Studio product from Expert Microsystems to train APR models
from historical plant measurements and the SureSense® run-time calculation engine. The latter
integrates with Uniformance Asset Sentinel and the first principle templates, to provide a comprehensive
view of Asset Performance, KPIs, Fault-Symptom recommendations and early warning of anomalies.
Note that the SureSense® products require an additional license from Expert Microsystems.

The purpose of this appendix is to provide an overview of the APR capability that can be optionally
provided with UAS, the templates available with Uniformance Asset Sentinel release 520.2 and an
overview of the implementation workflow.

APR Concept Overview

The Advanced Pattern Recognition models use historical operating data to define a baseline of the
normally expected behavior of an asset. This is captured as the normally expected correlations between
the variables measured for the equipment. A very simple example would be the correlation between the
pressure drop across a pump and the flow through the pump.

The model training process requires the user to screen out abnormal / faulty operating modes of the
equipment, retaining the normal operating behavior. The resulting models describe all the normally
expected combinations (or patterns) of the input signals.

For any new set of the input signals, these models can then be used to estimate the values of the
measured signals (termed the expected values). For each set of input data, a prediction error (or
residual) can therefore be computed by differencing the expected and measured values. The following
figure illustrates the concept.

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 Training

Signal A
Signal B APR Model
Signal C

Online

Signal A Signal A Expected Signal A Residual

Signal B
Signal C
APR Model Signal B Expected
Signal C Expected
- Signal B Residual
Signal C Residual

Returning to the pump example, the APR model is trained using the historical pump differential pressure
and flowrate information (for normal operation). The pump speed could also be used if this varied over
time.

The model is then used online with current measurements of differential pressure, flowrate (and speed)
to estimate values for the current differential pressure, flowrate (and speed). If the estimated values
differ significantly from the measured values, this is an indication of a potential pump malfunction.

From the training data, the prediction accuracy of the models is calculated from the statistical
properties of the residuals, which effectively provides a range of uncertainty in the model predictions.
Fault detectors are then configured to generate alerts if the residual of a monitored signals exceed a
threshold (which is selected to be above the uncertainty in the model predictions).

The following figure illustrates the concept for a single variable. The red dashed line represents the time
series trend of the expected measured value and the solid blue line is the measured value. The white
region around the expected value represents the alerting threshold above and below the expected value.
When the measured value deviates from the estimated value by more than the threshold, then a
potential fault condition is flagged. Note that the fault detectors are based on individual measured vs
expected values, but at least two correlated measurements are required for an APR prediction model.

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 Traditional Alarm Limit
Alert but late
Early
Warning
Value

Sensor

Expected
(from APR model)
Limit
(from APR model)
Time

Provided the APR models are representative, this is an effective mechanism to detect equipment
performance issues quickly with minimal false positives.

26.2 Templated Content

The Advanced Pattern Recognition approach described above is a generic method that can be applied to
any set of correlated signals. Furthermore, because the method relies on historical data, models cannot 1
be re-used “as-is” from one equipment item to another. As such it is not possible to exactly template the
APR models for different equipment types.

However, some skill is still required to define and train the APR models for different equipment types,
and some engineering effort is required to implement and visualize the results. Eight equipment
templates have therefore been developed for common equipment types that embody Honeywell’s
experience of applying APR models. The templates provide guidelines on how to group the typical
equipment measurements into sets of correlated measurements that are well suited to the APR method,
as well as providing utilities and templated graphics to reduce the implementation effort. The APR
templates for the following asset types are supported for the 520.2 release of Uniformance Asset
Sentinel:
1. Motor driven centrifugal pump;
2. Steam turbine driven centrifugal pump;
3. Electrical submersible pump;
4. Motor driven centrifugal compressor (n-stage);
5. Steam turbine driven centrifugal compressor (n-stage);
6. Motor driven reciprocating compressor;
7. Diesel engine driven generator;
8. Steam turbine driven generator.

1
Unless the equipment type, installed behaviour and mode of service are identical.

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The following sections summarize the APR template content. For each equipment type a template pack
is provided that contains:
o The SureSense® Studio template defining the model structure for typical equipment
measurements. This can be amended and extended based on the available instrumentation.
o An Excel based utility to reduce the Uniformance Asset Sentinel configuration effort together with
detailed configuration guidelines;
o A templated schematic in the form of importable HMIWeb Graphic files.

The complete template packages are provided as part of the APR model delivery.

Motor Driven Centrifugal Pump

A centrifugal pump is a mechanical device designed to move liquid by means of the transfer of rotational
energy from one or more driven rotors, called impellers. Liquid enters the rapidly rotating impeller along
its axis and is cast out by centrifugal force along its circumference through the impeller’s vane tips. The
action of the impeller increases the fluid’s velocity and pressure and directs it towards the pump outlet.

The pump casing is specially designed to constrict the fluid from the pump inlet, direct it into the
impeller and then slow and control the fluid before discharge.

The motor drive provides the rotational energy to the centrifugal pump. The APR template assumes a
three-phase AC motor; however, the template can be simplified for the single phase or DC motor.

Centrifugal pumps are commonplace on process plants. Some are spared and hence their impact on
overall plant reliability is relatively low, however, some are not spared and critical to maintaining the plant
throughput.

Health Monitoring covers the reliability aspect of the equipment and supporting components. The
following figure and table lists the measurements includes in the Motor Driven Centrifugal Pump APR
model

4
6 1
5 5 3 3 2

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 Key Measurement

Thrust Bearing Active Temperature

1
Thrust Bearing Non-Active Temperature
2 Shaft Displacement (typically 2 measurements)
Journal Bearing Vibration
3 Journal Bearing Temperature
Bearings Oil Temperature
Suction Pressure
4 Discharge Pressure
Flow
Journal Bearing Vibration
5 Journal Bearing Temperature
Bearings Oil Temperature
Current
Winding A Temperature
6
Winding B Temperature
Winding C Temperature
7 Shaft Speed

Visualization
The following figures illustrate the dashboards for the motor driven centrifugal pump. These will
normally be created with the templated graphics and trend elements from Insight. For a complete asset
view, the graphic elements can be combined with elements for the associated equipment such as driver,
gearbox or lubrication system (where available).

The dashboards are designed to provide awareness of location of potential faulty elements/subsystems.
The user can drag and drop the actual, expected, and/or limits to the top right the trend components.
Plotting the status in the lower bottom trend component enables the user to understand if an alert is
due to a persistent or temporary limit violation.

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Uniformance® Asset Sentinel
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Steam Turbine Driven Centrifugal Pump
The steam turbine driven centrifugal pump differs from the previous example in terms of the drive
providing the rotational energy. The steam turbine extracts energy from the high-pressure steam supply
as it expands to the discharge pressure and temperature. A single steam extraction is assumed in the
APR model; however, the model can be extended providing additional measurements are available.

Health Monitoring covers the reliability aspect of the equipment and supporting components. The
following figure and table included in the Steam Turbine Driven Centrifugal Pump APR model.

8 4

6 1
9

7 2

5 5 3
3

Key Measurement Used in APR Model

Thrust Bearing Active Temperature

1
Thrust Bearing Non-Active Temperature
2 Shaft Displacement (typically 2 measurements)
Journal Bearing Vibration
3 Journal Bearing Temperature
Bearings Oil Temperature
Suction Pressure
4 Discharge Pressure
Flow
Journal Bearing Vibration
5 Journal Bearing Temperature
Bearings Oil Temperature
Thrust Bearing Active Temperature
6
Thrust Bearing Non-Active Temperature
7 Shaft Displacement (typically 2 measurements)

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 Key Measurement Used in APR Model

Suction Pressure
Suction Temperature
8 Discharge Pressure
Discharge Temperature
Flow
9 Shaft Speed

Visualization
The following figures illustrate the standard Insight dashboard element for a centrifugal pump and the
dashboard for the steam turbine drive. These will normally be created with the templated graphics and
two trend elements from Insight. For a complete asset view, the graphic elements can be combined with
elements for the associated equipment such as driver, gearbox or lubrication system (where available).

The dashboards are designed to provide awareness of location of potential faulty elements/subsystems.
The user can drag and drop the actual, expected, and/or limits to the top right the trend components.
Plotting the status in the lower bottom trend component enables the user to understand if an alert is
due to a persistent or temporary limit violation.

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Electrical Submersible Pump
More than 90% of all producing oil wells require some form of artificial lift to increase the flow of fluids
from the well because the reservoir pressure is insufficient to support economic or optimum oil
production rates.

An electrical submersible pump (ESP) system comprises of both downhole and surface components.
The downhole pump is a multi-stage centrifugal pump whose stages are stacked; the operating
requirements of the well and completion design dictate the number of stages. Each stage contains a
rotating impeller and stationary diffuser. As well fluid flows into the first stage of the ESP, it passes
through an impeller, and the fluid is centrifuged radially outward, gaining energy in the form of velocity.
The pump casing is specially designed to constrict the fluid from the pump inlet, direct it into the
impeller and then slow and control the fluid before discharge converting the kinetic energy to potential
energy. The fluid then enters the next centrifugal stage to repeat the process. The centrifugal pump is
driven by an induction motor, often a variable speed motor.

The level of ESP instrumentation varies in practice, so it is difficult to define a truly typical set of
measured inputs. However, ESP vendors generally provide an optional sensor pack that measures
process and equipment condition parameters assumed for this template, as illustrated the following
figure and table.

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 Key Measurement Used in APR Model
Thrust Bearing Active Temperature
1
Thrust Bearing Non-Active Temperature
2 Shaft Displacement (typically 2 measurements)
Journal Bearing Vibration
3 Journal Bearing Temperature
Bearings Oil Temperature
Intake Pressure
4 Discharge Pressure
Separator Oil Flow
Journal Bearing Vibration
5 Journal Bearing Temperature
Bearings Oil Temperature
Current
Winding A Temperature
6
Winding B Temperature
Winding C Temperature
7 Shaft Speed

Visualization
The following figure and table illustrate the dashboard for the Electrical Submersible Pump. These will
normally be created with the templated graphics and trend elements from Insight. For a complete asset
view, the graphic elements can be combined with elements for the associated equipment.

The dashboards are designed to provide awareness of location of potential faulty elements/subsystems.
The user can drag and drop the actual, expected, and/or limits to the top right the trend components.
Plotting the status in the lower bottom trend component enables the user to understand if an alert is
due to a persistent or temporary limit violation.

Motor Driven Centrifugal Compressor (N-Stage)

Compressors are used to transport the gases and to increase pressure of gases in process plants, power
plants, and other industries. Compressor performance has a significant impact on the overall plant
performance in terms of energy usage, efficiency, and throughput. However, perhaps more importantly,
the availability of the centrifugal compressor is often critical to the operation of the unit and so the early
detection of potential equipment degradation is key to balancing the unit operation with the
maintenance needs.

Health Monitoring covers the reliability aspect of the equipment and supporting components. The
following figure and table lists the measurements included in the Motor Driven Centrifugal Compressor

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APR model. Note that measurements relate to a single stage compressor, but multiple stages of process
compression can be added to the APR models by duplicating the elements of the prediction models.

6
1
5 5
7
2

3 3
8 9

Key Measurement Used in APR Model

Thrust Bearing Active Temperature

1
Thrust Bearing Non-Active Temperature
2 Shaft Displacement (typically 2 measurements)
Journal Bearing Vibration
3 Journal Bearing Temperature
Bearings Oil Temperature
Suction Pressure
Suction Temperature
4 Discharge Pressure
Discharge Temperature
Flow
Journal Bearing Vibration
5 Journal Bearing Temperature
Bearings Oil Temperature
Current
Winding A Temperature
6
Winding B Temperature
Winding C Temperature
7 Shaft Speed

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Visualization
The following figure and table illustrate the standard Insight dashboard elements for a Motor Driven
Centrifugal Compressor. These will normally be created with the provided graphics and two trend
elements from Insight. For a complete asset view, the graphic elements can be combined with elements
for the associated equipment such as driver, gearbox or lubrication system (where available).

The dashboards are designed to provide awareness of location of potential faulty elements/subsystems.
The user can drag and drop the actual, expected, and/or limits to the top right the trend components.
Plotting the status in the lower bottom trend component enables the user to understand if an alert is
due to a persistent or temporary limit violation.

Steam Turbine Driven Centrifugal Compressor (N-Stage)

The steam turbine driven centrifugal compressor differs from the previous example in terms of the drive
providing the rotational energy. The steam turbine extracts energy from the high-pressure steam supply
as it expands to the discharge pressure and temperature. A single steam extraction is assumed in the
APR model; however, the model can be extended providing additional measurements are available.

Health Monitoring covers the reliability aspect of the equipment and supporting components. The
following figure and table lists the measurements included in the Steam Turbine Driven Centrifugal
Pump APR model.

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 8 4
6 1
9

7 2

5 5 3 3

Key Measurement Used in APR Model

Thrust Bearing Active Temperature

1
Thrust Bearing Non-Active Temperature
2 Shaft Displacement (typically 2 measurements)
Journal Bearing Vibration
3 Journal Bearing Temperature
Bearings Oil Temperature
Suction Pressure
Suction Temperature
4 Discharge Pressure
Discharge Temperature
Flow
Journal Bearing Vibration
5 Journal Bearing Temperature
Bearings Oil Temperature
Thrust Bearing Active Temperature
6
Thrust Bearing Non-Active Temperature
7 Shaft Displacement (typically 2 measurements)
Suction Pressure
Suction Temperature
8 Discharge Pressure
Discharge Temperature
Flow
9 Shaft Speed

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Visualization
The following figure and table illustrate the standard Insight dashboard elements for a steam turbine
driven centrifugal compressor. These will normally be created with the provided graphics and two trend
elements from Insight. For a complete asset view, the graphic elements can be combined with elements
for the associated equipment such as driver, gearbox or lubrication system (where available).

The dashboards are designed to provide awareness of location of potential faulty elements/subsystems.
The user can drag and drop the actual, expected, and/or limits to the top right the trend components.
Plotting the status in the lower bottom trend component enables the user to understand if an alert is
due to a persistent or temporary limit violation.

Motor Driven Reciprocating Compressor

Reciprocating compressors, like their centrifugal counterparts, are used to transport the gases and to
increase pressure of gases in process plants, power plants, and other industries. Compressor
performance has a significant impact on the overall plant performance in terms of energy usage,
efficiency, and throughput. However, perhaps more importantly, the availability of the reciprocating
compressor is often critical to the operation of the unit and so the early detection of potential equipment
degradation is key to balancing the unit operation with the maintenance needs.

From an APR standpoint the uniqueness of the asset is the typical set of available measurements.

Health Monitoring covers the reliability aspect of the equipment and supporting components. The
following figure and table lists the measurements included in the motor driven reciprocating
compressor APR model.

2 1

7 3 4
6 6
8 5

3 4

2 1

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 Key Measurement Used in APR Model

Cylinder Suction Dampener Pressure

Cylinder Suction Dampener Temperature
1
Cylinder Discharge Temperature
Cylinder Discharge Dampener Pressure
Cylinder Suction Valve Head-End Temperature
Cylinder Suction Valve Crank-End Temperature
2
Cylinder Discharge Valve Head-End Temperature
Cylinder Discharge Valve Crank-End Temperature
3 Packing Case Temperature
4 Rod Position
5 Bearing Temperature
Journal Bearing Vibration
6 Journal Bearing Temperature
Bearings Oil Temperature
Current
Winding A Temperature
7
Winding B Temperature
Winding C Temperature
8 Shaft Speed

Visualization
The following figure and table illustrate the standard Insight dashboard elements for a Motor Driven
Reciprocating Compressor. These will normally be created with the provided graphics and two trend
elements from Insight. For a complete asset view, the graphic elements can be combined with elements
for the associated equipment such as driver, gearbox or lubrication system (where available).

The dashboards are designed to provide awareness of location of potential faulty elements/subsystems.
The user can drag and drop the actual, expected, and/or limits to the top right the trend components.
Plotting the status in the lower bottom trend component enables the user to understand if an alert is
due to a persistent or temporary limit violation.

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Diesel Engine Driven Generator
There are two main types of diesel engines: two-stroke and four-stroke. Most diesel engines generally
use the four-stroke cycle, with some larger engines operating on the two-stroke cycle. Normally, banks
of cylinders are used in multiples of two, though any number of cylinders can be used providing the load
on the crankshaft is counterbalanced to prevent excessive vibration. The generator sets produce either
single or three phase power, although industrial or commercial applications usually require three phase
power.

Most modern generators are engineered to meet emergency power needs. These units continuously
monitor the electrical current and automatically start up if power is interrupted and shut off when utility
service is returned. In industries, during critical processes, generators can supply emergency power to all
vital and selected loads as desired.

Health Monitoring covers the reliability aspect of the equipment and supporting components. The
following figure and table lists the measurements included in the steam turbine driven generator APR
model.

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 3

7 4
2 1

Key Measurement Used in APR Model

Engine NDE Bearing Radial X Vibration

Engine NDE Bearing Radial Y Vibration
1
Engine NDE Bearing Axial Vibration
Engine NDE Bearing Temperature
Engine DE Bearing Radial X Vibration
Engine DE Bearing Radial Y Vibration
2
Engine DE Bearing Axial Vibration
Engine DE Bearing Temperature
Engine Cylinder Head Radial X Vibration
3 Engine Cylinder Head Radial Y Vibration
Engine Cylinder Head Axial Vibration

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 Key Measurement Used in APR Model

Engine Power Generation

Engine Fuel Mass Flow
Engine Air Mass Flow
Engine Air Intake Temperature
4 Engine Fuel Temperature
Engine EGR Valve Position
Engine Throttle Position
Engine Exhaust Temperature
Engine Exhaust O2 Content
Lubrication Oil Temperature
5
Crank-case Lube Oil Temperature
6 Engine Coolant Temperature
Generator Hot Air Collector End Temperature
Generator Cold Air Coupling End Temperature
Generator Cold Air Collector End Temperature
7
Generator Hot Air Coupling End Temperature
Generator Stator Collector End Temperature
Generator Stator Center Temperature
8 Engine Speed

The following figure illustrates the standard Insight dashboard elements for a diesel engine generator.
These will normally be created with the provided graphics and two trend elements from Insight. For a
complete asset view, the graphic elements can be combined with elements for the associated
equipment such as driver, gearbox or lubrication system (where available).

The dashboards are designed to provide awareness of location of potential faulty elements/subsystems.
Plotting the status in the lower bottom trend component enables the user to understand if an alert is
due to a persistent or temporary limit violation.

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Steam Turbine Driven Generator
A steam turbine driven generator, sometimes termed a turbo generator, is a combination of a steam
turbine and an electrical generator. The steam turbine extracts energy from the high-pressure steam
supply as it expands to the discharge pressure and temperature. A two-stage turbine is assumed in the
APR model; however, the model can be extended providing additional measurements are available. The
generator converts the mechanical energy into electrical energy, typically three-phase AC.

Health Monitoring covers the reliability aspect of the equipment and supporting components. The
following figure and table lists the measurements included in the steam turbine driven generator APR
model.

3 2
4
5 1 1 6 7

2 1 8

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 Key Measurement Used in APR Model

Journal Bearing Vibration

Journal Bearing Temperature
1
Bearings Oil Temperature
Bearing Oil Drain Temperature
LP Turbine Inlet Steam Pressure
LP Turbine Inlet Steam Temperature
LP Turbine Outlet 1 Steam Pressure
2 LP Turbine Outlet 1 Steam Temperature
LP Turbine Exhaust Steam Pressure
LP Turbine Exhaust Steam Temperature
LP Turbine Inlet Intercept Valve Position
HP Turbine Inlet Steam Pressure
HP Turbine Inlet Steam Temperature
HP Turbine Outlet 1 Steam Pressure
3 HP Turbine Outlet 1 Steam Temperature
HP Turbine Exhaust Pressure
HP Turbine Exhaust Steam Temperature
HP Steam Turbine Inlet Control Valve Position
Thrust Bearing Active Temperature
Thrust Bearing Non-Active Temperature
4 Thrust Bearing Active Oil Drain Temperature
Thrust Bearing Non-Active Oil Drain Temperature
Thrust Bearing Vibration
Generator Hot Air Collector End Temperature
Generator Cold Air Coupling End Temperature
Generator Cold Air Collector End Temperature
5
Generator Hot Air Coupling End Temperature
Generator Stator Collector End Temperature
Generator Stator Center Temperature
6 Steam Turbine Power
7 Ambient Temperature
8 Lube Oil Temperature
9 Shaft Speed

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Visualization
The following figure illustrates the standard Insight dashboard elements for a steam turbine driven
generator. These will normally be created with the provided graphics and two trend elements from
Insight. For a complete asset view, the graphic elements can be combined with elements for the
associated equipment such as driver, gearbox or lubrication system (where available).

The dashboards are designed to provide awareness of location of potential faulty elements/subsystems.
The user can drag and drop the actual, expected, and/or limits to the top right the trend components.
Plotting the status in the lower bottom trend component enables the user to understand if an alert is
due to a persistent or temporary limit violation.

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26.3 Implementation Workflow
A summary of the implementation steps is illustrated by the following figure and table.

Start

Select the Asset Type template Verify model with testing

in SureSense® dataset
1 7

Cross check the set of template Cross check the set of template
inputs against the available plant inputs against the available plant
2 measurements 8 measurements

Map plant measurements to Cross-check SureSense® online

template inputs dataset and Writer
3 9

Load Model training and testing Deploy SureSense Model to on-

datasets line engine
4 10

Select training and testing

datasets Complete
5

Train the model.

6

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Step # Description
Select Asset Type Template in SureSense:
Use SureSense® Studio to open the appropriate APR model template.
The template includes typical instrumentation available for the equipment
type and uses a naming convention that carries forward to the UAS asset
1
model.
The template also includes the signal grouping and fault detectors.
Save the template in the SureSense Project/Data store that will be used for
the project.

Cross-check Template Signals Against Available Measurements:

The degree of instrumentation can vary between equipment models and
2 vendors; therefore, the template signals need to be validated against the
available instrumentation. Signals can be subtracted or added from the
template list using the SureSense® Studio -> Observed Tags

Map Plant Measurements to Template Inputs:

To connect the template to the data sets, Tag names from the data source(s)
3 need to be mapped to the SureSense asset template.
The mapping between a data set and SureSense tag name is referred in
SureSense as an Alias.

Load Model Training/Testing Datasets:

4 Use any of the SureSense readers to load offline data for model training and
validation. The available readers allow loading data from CSV, text, and UAS
via the DAS plugin.

Select Training data:

5 The following section of this document provides some general guidelines for
the selection of training and validation data sets. Use the SureSense® User
Guide if you require assistance to create the training data sets.

Train the Model:

6 In SureSense® Studio, Run -> Calibrate -> Correlation Models and select the
Offline Data Set(s) for model training

Verify Model:
7 In SureSense® Studio, Run -> Test and select the Offline Data Set(s) for model
testing

8 Cross-check UAS Asset Template:

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Step # Description
To configure Sentinel to read and write from/to SureSense®, use the Template
and Asset Sheets within the Excel based utility.
If the original APR model input sets (standard SureSense® input templates)
were used without modification, the preconfigured template names can be
used without any modifications. However, if the input set was modified, the
utility needs to be used to modify the “Configuration” tab to reflect the
changes in the SureSense® template.
Follow instructions the instructions in the Template for SureSense -
Sentinel.pdf document to modify the UAS Asset templates.
Provide the “Template Sheets” and “Asset Sheets” from the Excel utility to the
person responsible for the UAS configuration.

Cross-check SureSense® Online data set and Writer:

To configure SureSense® to read and write from/to Sentinel, use the “Tag
Import” tab and .xml generated file from the Excel utility.
9 If the original APR model input sets (standard SureSense® input templates)
were used without modification, the Excel utility is not needed. However, if the
input set was modified, the utility needs to be used to modify the
“Configuration” tab to reflect the changes in the SureSense® template. This
would have been done in Step 8.

Deploy SureSense Model to the SureSense® Online Engine:

10 In the SureSense® Studio, click on File -> Deploy and deploy the APR model(s).
Use the configured Asset Sentinel OPC Online Data Set as the Select data set.

26.4 Data Requirements

A general guidance the data requirements for APR models is given below.

Relevance
Select signals that are relevant to the performance and/or reliability of the specific process or
equipment. Include any pressures, temperatures, flows, vibration data, valve positions or other signals
that impact this specific process or equipment. Signals such as ambient temperatures or load may also
impact the process or performance. The domain knowledge expert (subject matter expert) for the
process and/or equipment can be utilized to select the most relevant parameters for the monitoring
target.

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Well Correlated
When creating a good predictive model, select data signals that correlate well with each other. This
results in a good and accurate predictive model. Including data signals that are NOT well correlated may
decrease the accuracy of the predictive models. Do not include signals that are invariant within the
training set.

Operating Range
Include data over the normal range of operating conditions. For example, this may include a range of
loads (i.e. low load, mid-load, and high load) and transition periods if those are of interest (i.e. start-up,
ramp-up, and shut-down).

Data Quantity
APR models requires enough historical data for calibration to “train” the models on the range of normal
operating modes. In many cases, this means that the historical, calibration dataset needs to include any
seasonal variability and/or daily variability. Therefore, at least 12-18 months of historical data is desired,
ideally including the most recent time periods. This provides the most recent data to be used for
calibration. Smaller, supplemental datasets can be used which include details that represent short-term
variability trends (i.e. hourly or daily).

Data Frequency
Generally, on-line monitoring for reliability and performance is performed at 5 to 10 minutes intervals.
Therefore, the dataset used for calibration and monitoring should reflect this frequency. Remote
monitoring functions are usually not focused on detecting anomalies problems at shorter intervals as
there is little time to act. Shorter time-based monitoring is best performed at the plant level with existing
control system alarm settings.

In some cases, users are interested in transition events such as ramp-ups or start-ups. This requires a
dataset with a shorter time interval to capture these rapid changes. In this case, the historical dataset
and on-line monitoring frequency can be shorter. There is no limit in SureSense for data frequency.
However, the SureSense processing time is a function of the number of data variables and the frequency
of the data

Data Information
The dataset should include the following information for each parameter or data stream value:

Date/Time: Date and time the data stream value was collected/measured/recorded. It is important that
the Date/Time format be uniform if using multiple datasets.

DataTag Name: Unique name used in historian or database for this specific data stream value.

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Units: Unit of measure for the data stream value (i.e. %, psig, F, t/hr) This value is recommended but not
required.

Description of data stream value: Short description of data value for easier identification during
modeling, monitoring and display. For example, in addition to the datatag name of “14LBA50CT051”, a
description such as “Temperature HP steam header” might be included. This information is very helpful
but not required.

Alias (optional): Data name used by plant/fleet as generic reference to a similar asset. For example, for
the HP steam header temperature it might be: “AssetAbreviation_Location_TypeofMeasurement”. This
nomenclature can be helpful to standardize across several units.

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Contact Us

Seeking technical assistance

For technical queries, contact Honeywell Customer Support.

For contact information, visit:

https://www.honeywellprocess.com/en-US/contact-us/customer-support-contacts/Pages/default.aspx

Reporting a security vulnerability

For the purpose of submission, a security vulnerability is defined as a software defect or weakness that can
be exploited to reduce the operational or security capabilities of the software.

Honeywell investigates all reports of security vulnerabilities affecting Honeywell products and services.

To report a potential security vulnerability against any Honeywell product, follow the instructions at:

https://honeywell.com/pages/vulnerabilityreporting.aspx

Submit the requested information to Honeywell using one of the following methods:

o Send an email to [email protected].

o Contact your local Honeywell Technical Assistance Center (TAC).

Providing documentation feedback

To provide feedback about this document, or to report errors and omissions, write to us at:

[email protected]

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For more information
To learn more about Honeywell’s products or
solutions visit www.honeywellprocess.com or
contact your Honeywell account manager.

Process Solutions
Honeywell

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UASDOC-X481-en-531.1A
May 2020
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