¶ Sensor (Tag) Management
Sensors are referred to as Tags across the Platform. There can be a wide variety of Sensors used in a plant. They could be heat sensors, pressure sensors, voltage, frequency, vibration, speed, load, pressure deviation, and so on. Each sensor in the plant is given a unique identifier called "dataTagId" along with information such as instrument properties, its location in the plant, the property it measures, etc. All this information is added to a record called "tag meta" in the Database.
Let us, at the outset, know the hierarchical asset structure within a Plant.
Every Plant may have a number of systems, for example, Boilers, Cooling systems, Fuel Supply, Generators, Transformers, Turbines and many more. The system, therefore, is a collection of equipment that performs a specific function. The system is, thus, broken down at the first level into a set of Equipment or Assets.
The equipment/assets are usually self-sufficient machinery that contribute to a specific aspect of a system’s functioning. For example, Pre-heater is an equipment and is a part of the Boiler system.
Components and/or Sub-Components are the logical breakdown of an equipment like Economizer, Main Steam Lines, Supply Systems, Fans, Steam Pressure Controllers, Storage Tanks, Air Coolers, Furnaces and Bearings in case of sub-components, and such others.
Relevant Sensors (Tags) are attached to each Component or Sub-Component to record/monitor respective measure properties. The Measure Property is the medium or base property of the system that is being monitored. These measure properties could be, depending on the type of plant (Power Generating, Cement), Secondary Air, Metal, Power, Main Steam, Feed Water, Cooling Water, Flue Gas, Oxygen, Furnace, and such others to measure Differential Pressure, Current, Voltage, Frequency, Flow, Run Hours, Pressure Deviations, etc in terms of respective measure units like KG/Cm2, Kv, Mm/Sec, Tph, Hours, MTs, RPM, Kj/Kg, kW, Kva etc (measure types).
The Tag Mapper feature of Pulse Platform allows you to map or assign the Sensors (Tags) to Equipment/Assets, Components and/or Sub-Components, Measure Property, Measure Type, Measure Units, and Measure Location (the location at which the sensor is placed. For example, Inlet, Outlet etc. All the sensors when onboarded remain Unassigned until you assign them to the relevant System, Equipment/Asset, Component, Sub-Component.
Once assigned to the Sub-Component level, Measure Property, Measure Type, Measure Unit, and Measure Location must be assigned to create the metadata for the Sensor. For a selected sensor, you will assign these metadata parameters relevant to it.
Warning: Do not attempt to assign the Sensors unless you are well-versed with the Systems/Equipment/Assets and their measuring parameters.
¶ Assigning Sensors to Equipment/Components
Figure 49. Tag mapper page
To initiate the tag mapping activity,
Click Ops Center, and then click Tag mapper. The Tag mapper screen displays.
The screen has the following tabs:
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Equipment
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Component
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Sub-Component
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Measure property
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Measure Type
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Measure Unit
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Measure Location
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Bad direction
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Anomaly
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Query
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Begin the exercise from the Equipment tab. The Unassigned tab under Tags section displays a list of sensors that are not assigned to any System and Equipment.
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Select the required tag to be assigned. The description of the sensor helps you to decide the system to which it must be tagged. The System and Equipment columns of the Tags section display Unassigned.
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Now, select the System and Equipment from the Equipment section. To do this, start entering the initial letters of the equipment to search for it. The relevant systems/equipment display.
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Select the appropriate equipment and click Assign. The Unassigned count is reduced and the Assigned count increases by one. The tag now displays as Unassigned in the Components tab. However, the System and Equipment names display against the tag.
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Select the tag and search for the Component in the Components section. Select the relevant Component and click Assign. The tag is assigned to a System, Equipment, and a Component. The tag now displays as Unassigned under the Subcomponent tab, or Measure Property tab, if there are no subcomponents.
Note: The count of Assigned tags under Equipment is the total of unassigned and assigned tags under the other tabs, with the exception of tags with Anomalies. The total of the counts of unassigned and assigned tags with Anomalies is the same as that of those under the Equipment tab.
¶ Assigning Measuring Properties to Sensors
The Unassigned tab under Tags section of Measure Property displays a list of sensors that are yet to be assigned. Measure Property is the medium or the base property of the system being monitored.
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Select the required tag to be assigned. The description of the sensor helps you to decide the measure property to which it must be tagged. The Measure Property column of the Tags section displays Unassigned.
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Now, select the measure property from the Measure Property section. To do this, start entering the initial letters of the property to search for it. The relevant measure properties display.
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Select the appropriate measure property and click Assign. The Unassigned count is reduced and the Assigned count increases by one. The tag now displays as Unassigned in the Measure Type tab.
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Repeat the process of assigning the tag to the rest of the parameters - Measure Type, Measure Unit, Measure Location, Bad Direction, and Anomaly.
¶ Assigning Bad Direction to Sensors
Alarms, as already mentioned, are Low, Normal, or High in intensity. However, if you wish to make an alarm unidirectional, for instance, you need only the High bearing temperature alarm, specify badDirection = HIGH.
You can do this by assigning the required tag to one of the Bad Direction values.
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Select the required tag to be assigned from the Unassigned tab.
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Now, select the appropriate badDirection from the list and click Assign. The Unassigned count is reduced and the Assigned count increases by one.
¶ Assigning Sensors with Anomalies
There may be some non-KPI sensors (tags). The deviations on these non-KPI tags are reported as Anomalies. Anomalies are automatic warnings that the system generates based on deployed predictive models.
The Anomalies tab of Tag Mapper allows you to assign such sensors to one of the options in the Anomaly List.
To do this,
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Select the required tag to be assigned from the Unassigned tab.
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Now, select the appropriate badDirection from the list and click Assign.