ASSET INTELLIGENCE / SITE TO SIGNAL
One site view. Every asset explained.
Start with an overview of your site. Drill into each asset that requires attention, the diagnosis behind it and the recommendation to resolve it.
DEMO DATA · Use operations data to shift from planned to proactive maintenance.
01 / SITE OVERVIEW
Your site, one overview
Crude Distillation · one prioritised view across all monitored equipment.
Illustrative historian data
monitored assets
across your site
healthy
no action required
watch
review trend
action
maintenance priority
01 / 18 ASSETS
Control Valve App
Mechanical condition, response and loop behaviour.
2 action4 watch
02 / 12 ASSETS
Pump App
Hydraulic performance and mechanical condition.
1 action2 watch
03 / 9 ASSETS
Motor App
Electrical, thermal and mechanical health.
7 healthy2 watch
04 / 6 ASSETS
Heat Exchanger App
Heat-transfer performance, fouling and duty.
5 healthy1 watch
SITE PRIORITY / TODAY
Three assets need action across valves and pumps.
The example inventory contains two Action valves and one Action pump. CV-318 and P-410B are shown below; the other Action valve is in the remaining inventory. M-230 and E-220 remain on Watch for trend review and planned inspection.
THE COMMON TECHNICAL METHOD
The same evidence chain powers every app.
01 / CONNECT
Historian Data
Read existing tags continuously where the needed signals are available. Some fault modes may need additional measurements.
02 / CONTEXTUALISE
Asset + operating state
Map signals to equipment and compare behaviour only with relevant modes, loads and process states.
03 / DIAGNOSE
Fault-specific evidence
Convert trends and residuals into an explainable diagnosis, confidence and consequence.
04 / ACT
Maintenance priority
Recommend what to inspect, what to plan and what to keep monitoring. Show why.
03 / CONTROL VALVE HEALTH
Control Valve App Find the control problem behind the symptom.
Separates valve mechanics from loop tuning and process disturbance, so engineers can act on the actual failure mechanisms.
01Stiction
02Packing friction
03Response error
ROTATING ASSET · DRAG TO INSPECT
assets in this illustrative site
12 healthy
4 watch
2 action
Priority asset view
ILLUSTRATIVE SITE DATA
CV-318
Reflux control valve
LATEST EVIDENCE
27% travel error · cycling
DIAGNOSIS / NEXT STEP
Stiction developing; inspect actuator and packing.
ACTION
CV-204
Feed control valve
LATEST EVIDENCE
18% friction · rising
DIAGNOSIS / NEXT STEP
Packing-wear signature; plan online inspection.
WATCH
CV-115
Steam control valve
LATEST EVIDENCE
2.1% mean position error
DIAGNOSIS / NEXT STEP
Response and seating remain within envelope.
HEALTHY
CV-211
Cooling-water valve
LATEST EVIDENCE
0.8 s response · stable
DIAGNOSIS / NEXT STEP
No stiction, some overshoot.
HEALTHY
4 priority valves shown · 14 additional valves remain available in the full inventory view.
WHAT IT DIAGNOSES
Problems the app recognises
- Packing & bellows wear
- Hysteresis / stiction
- Broken spring / diaphragm
- Positioner calibration
- Positioner drift
- Stuck open / closed
- Controller performance: undershoot, overshoot, deadband & hunting
HOW IT WORKS
From signal to diagnosis
- Aligns command, actual position and process response
- Segments each movement and measures delay, travel and settling
- Compares behaviour across operating points and controller modes
- Separates mechanical friction from tuning or process disturbance
- Ranks evidence and turns it into a maintenance action
DATA REQUIRED
Minimum viable signal set
- Valve command or controller output
- Measured valve position*
* When valve position feedback is not available, valve process-anomaly diagnostics are available.
HOW IT INTEGRATES
From insight to action
- Reads existing valve, loop and process tags from the historian or your data lake
- Maps each valve to its equipment ID or functional location in your CMMS
- Signals a validated fault or symptom, priority and recommended task that can be turned into a maintenance notification
- Links the notification back to the supporting trend and diagnostic evidence
- Synchronises work status and maintenance feedback through the same integration pattern
Illustrative diagnosis · Control Valve
One asset, three answers: what, why, and what to do.
Every point on the wireframe is a tag you already own. To the right: the named fault, the evidence behind it, and the action the fitter works from.
Assets with findings
What it reads & why
Current values
Diagnosis · Watch
04 / PUMP PERFORMANCE
Pump App See hydraulic and mechanical degradation early.
Combines process and condition signals to distinguish cavitation, wear and off-design operation before availability is affected.
01Cavitation
02Hydraulic loss
03Bearing wear
ROTATING ASSET · DRAG TO INSPECT
assets in this illustrative site
9 healthy
2 watch
1 action
Priority asset view
ILLUSTRATIVE SITE DATA
P-410B
Product transfer pump
LATEST EVIDENCE
NPSH margin falling
DIAGNOSIS / NEXT STEP
Cavitation risk under current throughput; review suction constraint.
ACTION
P-101
Crude feed pump
LATEST EVIDENCE
2.4 mm/s · +11% / 30d
DIAGNOSIS / NEXT STEP
Early bearing trend; keep online and shorten review interval.
WATCH
P-210
Cooling-water pump
LATEST EVIDENCE
81% estimated efficiency
DIAGNOSIS / NEXT STEP
Operating close to expected hydraulic curve.
HEALTHY
P-330A
Reflux pump
LATEST EVIDENCE
Seal temperature stable
DIAGNOSIS / NEXT STEP
No seal, bearing or hydraulic anomaly detected.
HEALTHY
4 priority pumps shown · 8 additional pumps remain available in the full inventory view.
WHAT IT DIAGNOSES
Problems the app recognises
- Cavitation and suction-side restriction
- Hydraulic efficiency degradation
- Bearing, imbalance and misalignment signatures
- Seal stress and abnormal temperature rise
- Operation away from the best-efficiency region
HOW IT WORKS
From signal to diagnosis
- Builds an expected pump curve from clean operating periods when a pump curve is unavailable
- Normalises pressure, flow and power for speed and process state
- Combines hydraulic residuals with vibration and temperature trends
- Checks persistence across starts, loads and parallel-pump states
- Explains the most likely fault and operating consequence
DATA REQUIRED
Minimum viable signal set
- Suction and discharge pressure
- Flow rate
- Speed or drive frequency
- Motor current or power
- Useful extras: vibration, bearing/seal temperature and valve positions
Vibration data source. When vibration data is not available in the historian, it can come from existing online monitoring or periodic handheld routes such as Emerson, ACOEM or Fluke.
HOW IT INTEGRATES
From insight to action
- Reads process, drive and condition-monitoring tags from the historian or your data lake
- Maps the pump and its driven equipment to equipment IDs and functional locations in your CMMS
- Signals a validated fault or symptom, consequence, priority and recommended inspection as a maintenance notification
- Keeps the evidence link with the notification so planners can review the operating context
- Receives work-order status and inspection outcomes to confirm or refine the diagnosis
Illustrative diagnosis · Pump
One asset, three answers: what, why, and what to do.
Every point on the wireframe is a tag you already own. To the right: the named fault, the evidence behind it, and the action the fitter works from.
Assets with findings
What it reads & why
Current values
Diagnosis · Watch
05 / MOTOR CONDITION
Motor App Connect electrical load to mechanical condition.
Tracks load, temperature and vibration in operating context to expose degradation that simple threshold alarms miss.
01Phase imbalance
02Thermal stress
03Bearing / rotor
ROTATING ASSET · DRAG TO INSPECT
assets in this illustrative site
7 healthy
2 watch
0 action
Priority asset view
ILLUSTRATIVE SITE DATA
M-230
Cooling-water pump motor
LATEST EVIDENCE
Voltage imbalance 2.8%
DIAGNOSIS / NEXT STEP
Electrical imbalance is persistent; inspect at next planned stop.
WATCH
M-501
Crude feed drive
LATEST EVIDENCE
78°C · vibration nominal
DIAGNOSIS / NEXT STEP
Thermal margin is narrowing.
WATCH
M-110
Export compressor motor
LATEST EVIDENCE
Load 74% · stable
DIAGNOSIS / NEXT STEP
Current, temperature and vibration remain balanced.
HEALTHY
M-330
Reflux pump motor
LATEST EVIDENCE
Starts and run-up normal
DIAGNOSIS / NEXT STEP
No rotor, bearing or alignment anomaly detected.
HEALTHY
4 priority motors shown · 5 additional motors remain available in the full inventory view.
WHAT IT DIAGNOSES
Problems the app recognises
- Phase or current imbalance
- Overload and thermal stress
- Bearing and rotor degradation signatures
- Misalignment and imbalance
- Abnormal starts, run-up and load response
HOW IT WORKS
From signal to diagnosis
- Creates load-specific electrical and thermal baselines
- Compares phase behaviour and current features over time
- Correlates electrical evidence with vibration and driven-equipment state
- Removes expected changes caused by ambient and process load
- Prioritises persistent cross-signal evidence over isolated alarms
DATA REQUIRED
Minimum viable signal set
- Motor current and running status
- Power, voltage or drive load where available
- Speed or drive frequency
- Useful extras: vibration and ambient temperature
- Optional: winding or bearing temperature
Vibration data source. When vibration data is not available in the historian, it can come from existing online monitoring or periodic handheld routes such as Emerson, ACOEM or Fluke.
HOW IT INTEGRATES
From insight to action
- Collects electrical, drive, temperature and vibration data from the historian or your data lake
- Associates each motor and driven asset with its equipment hierarchy in your CMMS
- Signals a maintenance notification only when persistent evidence reaches the agreed action threshold
- Passes the suspected fault, operating consequence and recommended test to the maintenance team
- Uses completed inspection and work-order feedback to close the reliability learning loop
Illustrative diagnosis · Motor
One asset, three answers: what, why, and what to do.
Every point on the wireframe is a tag you already own. To the right: the named fault, the evidence behind it, and the action the fitter works from.
Assets with findings
What it reads & why
Current values
Diagnosis · Watch
06 / HEAT-EXCHANGER PERFORMANCE
Heat Exchanger App Make lost heat-transfer performance visible.
Turns temperatures, flows and pressure drop into a clean performance view that separates fouling from changing duty.
01Fouling
02Pressure drop
03Duty loss
ROTATING ASSET · DRAG TO INSPECT
assets in this illustrative site
5 healthy
1 watch
0 action
Priority asset view
ILLUSTRATIVE SITE DATA
E-220
Cooling-water shell-and-tube exchanger
LATEST EVIDENCE
UA −9% / 60d
DIAGNOSIS / NEXT STEP
Fouling trend developing; review monthly. Projected clean window: about 5 months if the trend and duty remain unchanged.
WATCH
E-301
Feed preheater
LATEST EVIDENCE
Approach 8.4°C · stable
DIAGNOSIS / NEXT STEP
Heat-transfer effectiveness remains inside envelope.
HEALTHY
E-118
Gas aftercooler
LATEST EVIDENCE
ΔP 0.31 bar · stable
DIAGNOSIS / NEXT STEP
No fouling, restriction or imbalance detected.
HEALTHY
E-405
Product cooler
LATEST EVIDENCE
Duty tracking target
DIAGNOSIS / NEXT STEP
Performance follows throughput and seasonal context.
HEALTHY
4 priority exchangers shown · 2 additional exchangers remain available in the full inventory view.
WHAT IT DIAGNOSES
Problems the app recognises
- Fouling and heat-transfer degradation
- Increasing pressure drop or flow restriction
- Maldistribution and stream imbalance
- Abnormal approach temperature
- Potential leakage or unexpected duty loss
HOW IT WORKS
From signal to diagnosis
- Reconciles hot- and cold-side energy balance
- Calculates duty, approach and normalised heat-transfer coefficient
- Corrects for flow, inlet temperature and operating mode
- Tracks clean-baseline deviation and rate of degradation
- Forecasts the economic or operational cleaning window
DATA REQUIRED
Minimum viable signal set
- Hot-side inlet and outlet temperature
- Cold-side inlet and outlet temperature
- Flow on at least one side; both sides preferred
- Inlet/outlet pressure or differential pressure
- Useful extras: composition, bypass position and cleaning history
HOW IT INTEGRATES
From insight to action
- Reads temperatures, flows, pressures and operating state from the historian or your data lake
- Maps the exchanger to its equipment ID, functional location and maintenance history in your CMMS
- Signals a maintenance notification when degradation reaches an agreed cleaning or inspection threshold
- Includes the estimated performance loss, forecast window and evidence link for planning
- Returns cleaning dates and work results to the app so the post-maintenance baseline can be verified
Illustrative diagnosis · Exchanger
One asset, three answers: what, why, and what to do.
Every point on the wireframe is a tag you already own. To the right: the named fault, the evidence behind it, and the action the fitter works from.
Assets with findings
What it reads & why
Current values
Diagnosis · Act now
FROM DEMO TO YOUR SITE
See what your own plant data can tell you.
Start with one operating area, its critical assets and the historian tags already available. We will review which questions the data can answer and what is needed to investigate further.