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Feature Report
A Holistic Approach for
Pump-System Analytics
A step-by-step approach is presented to address the modern requirements of a
pump-system digital solution
Stylianos Giannoulakis
Sulzer Management Ltd.
n recent years, significant devel­
I
opments have been achieved in
the fields of cloud computing and
machine learning techniques. In
conjunction with increased aware­
ness regarding the benefits of digi­
tal transformation, from both users
and manufacturers of industrial
equipment, a unique opportunity is
emerging. This article describes a
comprehensive solution for address­
ing pump system monitoring, and
predictive and optimization analytics
in a holistic manner. The target of the
proposed approach is to leverage all
available system data and infrastruc­
ture and to address issues of tradi­
tional monitoring solutions. Typically,
traditional performance monitoring
and predictive solutions are simply
accepting errors of raw sensor data
or modeling assumptions, or both.
In addition, any reliability alerts are
based on thresholds of individual
sensors, which are usually triggered
at the time of failure, providing no re­
action time to the user.
As shown in Figure 1, five distinct
steps are defined as part of an inte­
grated solution: 1) connect remote
industrial equipment to the internet;
2) monitor the state of the equipment;
3) analyze the operating conditions;
4) predict the behavior of individual
components and of the complete
system by training customized mod­
els; and 5) optimize a pump system
at the aspects of performance ef­
ficiency, reliability and profitability.
This article presents the background
of the successful deployment of the
first three steps to a major pipeline
operator, along with the current re­
45675895
search and development efforts to
cover the remaining two steps. Collect all data m the
central cloud database
for doud computing
Connectivity
Different connectivity options are
available today, however the pre­
ferred solution will exploit existing
Define the state of
infrastructure. Typically, most pump every component at
every moment
systems of medium or high criticality
are equipped with a certain number
of permanent sensors, registering
values of fluid volumetric flow, pres­
Evaluate impact of
sures, density, pump status, vibra­ historical operation
tions, temperatures and driver en­ Analyze to performance and
reliability
ergy consumption. All sensor values
are stored in a central local database
and can be accessed by the opera­
tor. The proposed solution extends Simulate operating
the process by fetching all required conditions and predict
imminent failures
values from the local database and
transferring it to a cloud solution (Fig­
ure 2). This approach leverages ex­
isting infrastructure, does not disrupt
Minimize energy
existing operations and delivers all consumption and
Optimize
necessary data to a cloud environ­ maximize reliability
index
ment, which offers global access to
multiple users and leverages modern FIGURE 1. Visual representation of a step-by-step
techniques of cloud computing. approach for pump system analytics
Raw sensor data are averaged for
a short pre-defined time interval (typ­ to push the required data, but at the
ically in the range of a few minutes) same time ensuring that no access
and a selection of monitored param­ is possible through the firewall. Each
eters are concentrated into a file, file pushed from the user includes
which is subsequently pushed to a sensor values as a representation
secure cloud service. The data trans­ of the equipment’s operating con­
fer is only one way, enabling the user ditions for a discrete timestamp. All
Data Customer Queue Workers Cloud Cloud
push firewall services database
np
□n
FIGURE 2. This diagram shows the automated data flow of asset-sensor values to the cloud infrastruc­
ture for further evaluation
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data files end up at the cloud land­ information is also stored in the same Physical
ing zone, where they are queued for database, which characterizes the process

the first levels of pre-processing. A different components of the physical

/*\
selection process takes place ensur­ process. Such model parameters
Data
ing proper sequencing of data ac­ define the nominal expected behav­ historian
s________ _________ 4
cording to their timestamps. Other ior of the equipment.
standardization layers ensure that The first step of the process is to -
Cloud database
data are converted into default units evaluate the collected data for every Raw sensor values Evaluate
of measure and they are structured timestamp. Targeting to minimize model parameters operation
asset topology
to a relational database. The data both the measurement errors and ------- A --------
are structured following the relations the model uncertainties, a data-
Corrected
and topology of physical equipment. reconciliation method is employed. conditions

More details on the topic of equip­ Such a method leverages conser­

Data
ment topology are provided below. vation equations and component reconcilliation
modeling, to correct both measure­ ■■ --
2
Analytics architecture ment values and model parameters. Starting Conected
guesses models
Physical
models
This section discusses the overall The adapted values are stored back ■ ■
data flows and analytics algorithms, to the database and they will be the Simulation
providing a better understanding of basis of all downstream calculations.
the targeted architecture, which is After establishing the monitoring Adjust Conditions

shown in Figure 3. calculation, the user can assess the conditions evaluation

I_______ £
Following the standardization path impact of the validated operating
of the previous section, for every conditions of the asset along with the Optimization

new timestamp, raw sensor values deviation of corrected model param­

are stored in the cloud database. eters by comparison to the nominal FIGURE 3. Shown here Is an overview ot data

Apart from operational data, static ones. The latter can provide insights flows and analytics algorithms

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on degradation patterns over time.
Corrected model parameters of
recent operation are used to simu­
late the performance of the pump
system. Instead of relying on theo­
retical values, the system perfor­
mance is estimated based on the
latest measurements. Last but not
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34
45675895
simulations, to identify the optimal
operating conditions satisfying the Inlet ^ Outlet
user's requirements for overall sys­
tem performance.
4> ‘
Downstream calculations are also
leveraging the monitoring results.
Deviations from the pump's best ef­ Inlet
&
Electrical
driver
ficiency point (BEP) provide insights
to both performance losses and ac-
FIGURE 4. This diagram shows a pump/electrical-
driver system with measurements tor volumetric
flow (0), pressure (Pi, suction, discharge, rotational
speed (/V) and electrical current (/)
r cumulated impact on the pump’s
reliability. Finally, machine learning
algorithms are employed to identify
abnormalities in pump operation and
to notify the user in case of an im­
minent failure.
From monitoring to analytics
Following a digital-twin monitoring
approach, a physical representa­
tion of the system (in addition to the
sensor data) is required. Input shall
be provided concerning the system
topology, along with technical char­
acteristics of the individual assets
(that is. pumps, drivers, couplings,
pipes, valves, sensors and so on).
The combination of operational data
and system characteristics offers the
basis for pump-system monitoring.
In a traditional monitoring system,
every component is evaluated based
on nearby sensor measurements
and the overall performance of the
system by using a subset of the
local sensors. In the proposed ap­
proach, local raw measurements are
combined with equipment topology
and modeling. This strategy enriches
the available sensor data, imposing
physical and numerical constraints to
the solution.
In detail, a steady-state network
flow approach is followed to con­
struct the analyzed pumping system.
System equipment (pump, pipe,
valve, electrical driver and so on) are
+1.203.949.8697
represented as system nodes and
pre defined physical equations de­
scribe their behavior. The combina­
tion of these nodes can represent
complex pumping configurations.
During the digital-twin configuration,
node combinations define the asset
topology. Furthermore, a number of
model parameters need to be speci-
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TABLE 1. MEASUREMENT AND MODEL ADAPTATION RESULTS FOR SAMPLE PUMP

Variable Unit Raw Adapted Confidence

0, m3/s 0.120 0.121 0.83% 95%

Pi kPa 100 100 -0.04% 95%

h A 117.0 116.1 -0.77% 95%

1 rpm 3.580 3.580 0.00% 95%

£ L,
P4 kPa 2,600 2,626 1.00% 95%

A Efficiency ’ - 1.0 0.824 -17.60% 80%

A Head1 - 1.0 0.945 -5.50% 80%

1 (superscript) model parameters correcting the nominal pump performance (efficiency and head coefficient)

tied to describe the nominal perfor­ Where, y and z are the raw mea­
mance of the specific equipment. sured and non-measured param­
All required topology and model eters, v and i are the adapted
parameters are stored in a central parameters respectively, A is the in­
cloud database to be accessible by cident and V the variance matrices.
the analytics algorithms. A simplified example is shown
Both process data and equipment in Figure 4, where a number of
modeling suffer from some degree measurements are available for
of error, either random or system­ a pump/electrical driver system.
atic. A data-reconciliation method One can also take into account the 05$ 0
is applied, inspired by applications physical modeling equations that
in chemical and power plants [7]. describe the expected behavior
Such methods are able to evaluate of the system. In such a case, an
0
non-linear models of equipment. overdetermined system is derived,
They rely on data redundancies (that where measurements will not fit
is, sensor values, equipment topol­ the nominal expected behavior of
ogy and physical equations), to op­ the components. A data-reconcili- VERTICAL DRYERS
timally adjust measured quantities ation method is applied and Table
and model parameters by respect­ 1 illustrates the corresponding re­ FOR SOLIDS
ing problem constraints and con­ sults. It is noted that depending on
servation equations. This method the amount of confidence given to FROM PASTY TO FREE FLOWING
derives the most probable operating measurements and model param­
conditions of both the complete sys­ eters, the adaptation results can
tem and of individual components vary. In this example, higher confi­ ■ MINIMUM POWER INPUT
(pumps, motors, pipes, valves and dence is given to measured values
so on). This global approach reduces and lower to model parameters, ■ GENTLE VERTICAL MIXING
the level of uncertainty for
■ HOMOGENOUS TEMPERATURE
every evaluated timestamp 150
and derives customized DISTRIBUTION
component characteristics 425

according to the latest sta­ ■ OPTIMIZED FOR MAXIMUM

400
tus of the equipment. Any DISCHARGE DURING EMPTYING
general data reconcilia­
375
tion procedure must solve
E
the following constrained ■b 350

least-squares problem; ze§:

EKAT0 WEBINAR SERIES
that is, to minimize Equa­ 325

tion (1) subject to the con­ Nominal Curve https:f/www.ekato.comfenjekatogroup|

straint of Equation (2): 300 Best Efficiency Point (BEP)
Preferred Operating Region iPOR) workshops and seminarsl
Allowable Operating Region (AOR>
275 Limited Operating Region (LORI
Minimize: Restricted Operating Region (ROR)
Sensor Data
J(>\t) = <y-y)rV-l(y-y)
250

(1) 0 00 0-02 0.04 0 06 0 08 0.10 Your fast lane to production:

Flow, m3/s Phone: 1 201 825 4684 Ext.: 205
Subject to; FIGURE 5. This graph shows the comparison between usa@ekato.com
Ay y + A.J = 0 (2) sensor data and the nominal curve and recommended
operating regions
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CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM SEPTEMBER 2020 35

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Pump TABLE 2. SIMULATION PARAMETERS FOR SAMPLE PUMP - ELECTRICAL DRIVER SYSTEM
Inlet Outlet
Variable Unit Nominal Degradation Type
R > -----------
0, m3/s 0.120 0.120 Condition
O, = 0.12 m3/s
P, = 100 kPa « W, = 3.5B0 rpm kPa 100 100 Condition
k

% A 100.18 114.94 Result

Inlet
Electrical
n driver »3 rpm 3,580 3,580 Condition

kW 383.2 439.7 Result

",03
FIGURE 6. This diagram shows a pump/electrlcal-
04 m3/s 0.120 0.120 Result
driver system with volumetric flow (0), suction
pressure (Pi and rotational speed (A/) as system 2.789 2,642 Result
P< kPa
boundary conditions

which corresponds to higher adap­
tations for the model parameters.
Moreover, the sensor data of the
evaluated timestamp, indicate that
the pump performance is deviat­
ing (18% for efficiency and 5% for
head) from the nominal expected
behavior. Increasing deviation over
time can be an indication of perfor­
mance degradation.
Additional constraints can be
added to the system, by increas­
ing the number of available sensors
and the complexity of the pump­
ing system. This leads to a prob­
lem closer to the scale of modern
pumping systems and data recon­
ciliation is proven an appropriate
method for reducing measurement
and model uncertainties.
Every timestamp is evaluated fol­
lowing the above methodology,
Start of operation alter maior , >
maintenance action
Time
Train healthy model from
operation data
2,200
--------- v.
2.100
2.000 X 2.000
31.900
M *
31,800
1*1,600
and this offers greater confidence
on the collected data set for analy­
sis. The analysis step will provide a
clear picture of the current and his­
torical operation of every pump and
the rest of the equipment. For every
component, the validated operating
conditions can be compared to the
nominal and preferred operation. Ei­
ther by using API or a vendor's rec­
ommended zones, pump operation
will be evaluated. A visual compari­
son between real operating data and
recommended operating regions is
shown in Figure 5.
Conclusions can be drawn con­
cerning the equipment’s perfor­
mance and reliability status. Not only
performance, but also the pump’s
reliability are influenced by deviating
from best efficiency point (BEP) flow-
rate, for example through the dam-
Fwst clear model indication
of anomalous operation
1
Z to derive the operating conditions
Tram model with Predict failure
Period m advance of failure
marked by model as
healthy data using trained model
Identify abnormalities
2,200
2.100
X* \
V 3 1.900 %\
•\
\
3 1,800 \
\ x 1,700 \
aging effects of part load recirculation
[2). The impact of historical operation
can be analyzed, providing insights
on operational improvements.
Performance and reliability
Greater financial value for the user
can be achieved when predictions
are made concerning the future
equipment operation. Perfor­
mance predictions can offer sig­
nificant insights about the system
capabilities. The user is able to
test different operational scenarios
and assess their impact. This can
improve the scheduling of future
operation and match demand with
supply requirements more accu­
rately. The proposed solution of­
fers performance predictions for
pump systems by leveraging the
derived customized equipment
characteristics, as described in the
Stop of operation previous paragraph. In combina­
after failure
tion with the system topology and
specified boundary conditions,
the user shall trigger simulations
of individual components and of
anomalous the complete system. The simula­
tion process involves the complete
pump system calculation and the
final solution shall fulfill all physical
04/03/17 00:00 modeling equations.
As in the previous section, a simu­
lation example of a simplified pump/
electrical driver system is shown
in Figure 6 and the correspond­
Measurement
ing results in Table 2. Comparison
date
results are provided by both using

the nominal pump-performance

1.600

1.500
\

1,500 \t characteristics and by applying the

degradation factors, as calculated
700 800 900 IjOOO 1.100 1.200 1.300 700 600 900 1.000 1.100 1.2001,300 11/02717 00:00 in the previous section. As expected
Corrected ttOw. m^/h Corrected flow, nAlti
in comparison to nominal behavior,
FIGURE 7. The sequence at the top shown how an unsupervised machine-learning anomaly-detection
the pump discharge pressure is de­
algorithm works over time. The benchmark model is trained from healthy data (graph, lower left), which
can then be used to identify operational abnormalities (graph, lower right) creased, whereas the power con-

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Pipeline model
adaptation sumption is
E/kWh increased.
Physical
modeling of
every compo­
nent is similarly
C/ml/s
used as in the
orp
data recon­
ciliation step.
The model­
Pump model
♦ adaptation ing equations
describe con­
servation laws
FIGURE 8. Shown here Is a multiple-target optimiza­
tion problem of a pump system. Underlying perfor­
mance models are adapted to represent latest equip­
and the equip­
ment's per­ &
ment behavior
formance. In
comparison to
data reconciliation, where an overdetermined system is
resolved, in simulation, the number of unknowns matches
exactly the available equations. This requirement dictates
the necessary number of parameters that need to be
specified in advance as system boundary conditions (in
this example, it is equal to three). An approach for solving
nonlinear equations is employed [3], by iteratively solving
a system of linear equations:
The powder makes
Solve per iteration:
A. ■ dz = -F (3) the difference
Apply corrections: To make superior powders, look
i = z.+ dz (4)
for a GEA drying system.
Where, z are the original unknown parameters and z
are the calculated parameters by applying the respec­
GEA specializes in industrial drying
tive corrections 8c, Az is the Jacobian and F the re­
systems designed to match your exact
sidual matrices.
product and plant specifications.
Following the proposed methodology, complex
pump systems can be simulated. Where the perfor­ Our comprehensive product range

mance characteristics of each component shall be includes spray dryers, fluid bed

adapted in advance, according to recent sensor val­ systems, Hash and ring dryers, rotary

ues and data reconciliation results. This approach dryers and spray drying absorption

offers a great number of what-if scenarios for evalu­ plants. In house test facilities and
ating the current performance of the pump system. customer-oriented service concepts
The operator shall test the operating requirements guarantee a seamless support for
by performing system simulations, reflecting the dif­ instant productivity and performance.
ferent operating scenarios available. Due to the na­
ture of the approach, boundary parameters can be For contact details: gea.com/contact

specified according to the desired operating condi­

T
tions. In case the throughput is of major interest, the
ft
volumetric flow is provided as a boundary condition ■V

and the system should resolve the other parameters.

Similarly, if discharge head or pump operation close
to BEP are of interest, these are defined as boundary
i
conditions.
Concerning reliability predictions, the target of the engineering for
proposed approach alerts the user with sufficient no­
tice, in order to prevent an imminent failure. A clear G£A 9 better worW

benefit is gained through applying corrective mea­

sures before the failure even occurs. It can reduce
For details visit adlinks.chemengonline.com/76994-23

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM SEPTEMBER 2020 371

T.--. --

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Optimization
“ results
does not rely on individual sensors boundary conditions and trigger
threshold values. Instead, multiple simulations of the pump system
--- Pareto front
sensors are combined together, digital twin. The optimizer shall
pump key performance indicators evaluate the simulation results and
are evaluated and compared to their classify them according to the pre­
Distance from BEP, %

expected value. In several cases, defined target or targets. Several

this approach can provide an indi­ simulation optimization methods
cation of the developing issue much are available in the literature (for
earlier than the traditional threshold­ instance, gradient-based search,
monitoring approach. The latter heuristic methods and so on), a
y

usually triggers an alert only sec­ critical review of available methods

onds before the actual failure. is presented in Ref. 6.
Distance tram throughput target. %
An example of the expected op­
FIGURE 9. Shown here is a pareto front between Optimization capabilities timization results is shown in Figure
two competing targets of a pipeline system By establishing performance and 9. In case of two competing targets
reliability predictions, the next tar­ (that is, maximum system through­
get of this solution is to offer opti­ put and pump operation at BEP), a
the number of catastrophic failures, mization capabilities to the user. An number of optimal solutions formu­
which have a significant impact on optimizer shall trigger simulations late a pareto front. The algorithm of­
repair costs and downtimes. To of the pump system and based fers a number of viable solutions to
achieve this reliability goal, machine­ on an optimization strategy and the operator to choose from. ■
learning techniques are employed. boundary conditions, the opera­ Edited by Gerald Ondrey
More precisely, a combination of tion can be optimized for single or
unsupervised anomaly detection multiple targets. The pump system Note
with pump-physics-driven modeling performance can be optimized, by This article was first presented at the
is selected. While the specificity of ensuring the minimum energy is VDMA’s 4th International Rotating
anomaly detection techniques can consumed for given load require­ Equipment Conference, Wiesbaden,
be inadequate, the problem space ments. Another target can be the Germany, September 24-25, 2019.
may be reduced considerably by operation shift close to preferred
imposing constraints on variables, conditions, achieving also maxi­ References
especially by modeling the correla­ mization of the reliability index. t Romagnt*. j A and Sandie M C. 'Data Piocessng and Rec
cnckafon lor Chemical Process Operations' Academe Press
tions between components [ 4 ] , Furthermore, the use of drag-re­ CaHomo, 2000

The target is to determine if a ducing agents can be optimized, 2. Guteh. JF. 'Centntjgal Pumps' 2nd ed. Sponge* Heidelberg.
Germany. 2010.
pump is operating according to by ensuring at the same time that
3. larock, BE . Jeppson. R W. and Waters GZ, 'Hydraics d
normal operation standards or ab­ the pump system will operate at Pipe*ne Systems' CRC Press Ftenda. 1999

normality evidence is indicating an the desired conditions. It is appar­ 4. Snendsen, N„ WtWwsetr, S, Using ftiysica! Models tot Anomaly
Detection In Control Systems rr Palmer. G. Sbenoi, S. Critical
imminent failure. For that reason, ent that all discussed optimization nlraskucture Protection n HP Adiances n Womnation and

the training data are used to learn a strategies also have a positive im­ Commincabon TedmolOQy, »ol 311 Springer, Berfn. Hedel-
berg.2009.
model of the normal behavior. When pact on the financial targets of the 5. Pmentel MAE Ctfwi DA. CHIon. L and Tarassento. L, A
doing inference, new data are com­ system operation. Review ol Novedy Detecaon. Signal Processing, vol 99. pp
215-249.2014
pared to the expectation and then An optimization example is 6. Carson. Y and Mara. A. SrrUation Optrv/aton Methods and
classified. A review of common such shown in Figure 8, where compet­ Appkallons Proceertngs ot He 1997 Weller Simutatai Con
lerenoe, Atlanta. Ga, t. pp. 118-126,1998.
methods can be found in Ref. 5. As ing targets are illustrated. A typi­
seen in Figure 7, after every major cal target of a pipeline operator is
maintenance action of the pump, throughput maximization. In addi­ Author
a model representing the healthy tion, any reduction in operational Stylianos Giannoulakis is a data
scientist and machine diagnostics
asset is trained, which is used as costs (that is, electricity or fuel
engineer in the Global Technology
the benchmark model for any future consumption) is of great inter­ division of Sulzer Pumps Equip­
’
operation. Such models shall rep­ est. Last but not least, ideally all ment (Neuwiesenstrasse 15,
8401 Winterthur, Switzerland:
resent the pump healthy operation pumps shall operate as close as
Email: stylianos.giannoulakis®
at the full range of operating con­ possible to their BEP, to ensure sulzer.com) He received a Di­
ditions. For every new timestamp performance and reliability ben­ ploma in Mechanical Engineering
from National Technical University
available, the pump conditions are efits. Based on the established of Athens (NTUA) and an M.Sc. in Energy Science and
compared to the healthy benchmark data reconciliation method, physi­ Technology from Swiss Federal Institute of Technology
model and every deviation and ab­ cal pump and pipeline models are (ETH Zurich). He leads data analytics, machine learning
and software development prototyping for pumps
normality is a potential indication of adapted to represent the current equipment. He supervises the complete lifecycle of
a developing issue. equipment behavior. data analytics activities, from research/prototyping to

The key point of the proposed In the proposed approach, an operationalizing new product developments as cus­
tomer products offerings.
solution is that such a method optimization method shall set the

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