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| # CSH2 Cryogenic Pump — Diagnostic Reasoning Chains | |
| # Step-by-step decision trees encoding how an expert reasons from observation to diagnosis. | |
| # Each step specifies: what tool to call, what to look for, and branching rules. | |
| reasoning_chains: | |
| - id: RC-001 | |
| name: "Low Pressure Build Diagnostic" | |
| trigger: "PT130 cannot reach target pressure" | |
| related_failure_modes: [FM-001, FM-002, FM-003, FM-007] | |
| steps: | |
| - step: 1 | |
| action: "query_sensor_data" | |
| description: "Pull PT130, PT110, TT110, VFD speed for the time window" | |
| parameters: | |
| tagindices: [18, 17, 24, 13] | |
| look_for: "PT130 plateau level, PT110 stability, TT110 trend" | |
| next: | |
| if_pt130_below_50pct_target: "step_2" | |
| if_pt130_slow_build: "step_5" | |
| - step: 2 | |
| action: "run_simulation" | |
| description: "Compute expected PT130 at current operating conditions" | |
| parameters_from: "extracted operating conditions" | |
| look_for: "Sim vs measured gap magnitude" | |
| next: | |
| if_gap_gt_20pct: "step_3" | |
| if_gap_lt_20pct: "step_6" | |
| - step: 3 | |
| action: "Run DCV leak test" | |
| description: "Check PT130 decay rate with pump stopped" | |
| look_for: "Decay rate in bar/min" | |
| next: | |
| if_decay_gt_5_bar_per_min: "conclude_FM002" | |
| if_decay_lt_5_bar_per_min: "step_4" | |
| - step: 4 | |
| action: "Compare pressure build at multiple speeds" | |
| description: "Run pump at 10%, 30%, 50% speed and compare pressure" | |
| look_for: "Does pressure gap worsen at higher speeds?" | |
| next: | |
| if_worse_at_higher_speed: "conclude_FM001" | |
| if_similar_at_all_speeds: "step_5" | |
| - step: 5 | |
| action: "Check inlet conditions" | |
| description: "Verify subcooling margin: T_sat(PT110) - TT110" | |
| look_for: "Subcooling margin in K" | |
| next: | |
| if_margin_lt_2K: "conclude_FM007" | |
| if_margin_gt_2K: "step_6" | |
| - step: 6 | |
| action: "search_domain_knowledge" | |
| description: "Search maintenance history for recent ICV/DCV work" | |
| parameters: | |
| category: "maintenance_history" | |
| component: "ICV" | |
| look_for: "Recent maintenance events" | |
| next: | |
| if_recent_icv_work: "conclude_FM001_installation" | |
| if_no_recent_work: "conclude_FM003" | |
| conclusions: | |
| conclude_FM001: | |
| diagnosis: "ICV reverse flow — leak worsens with speed" | |
| confidence: "high" | |
| failure_mode: FM-001 | |
| conclude_FM001_installation: | |
| diagnosis: "ICV installation issue — recent maintenance" | |
| confidence: "high" | |
| failure_mode: FM-001 | |
| conclude_FM002: | |
| diagnosis: "DCV leakage — static pressure decay" | |
| confidence: "high" | |
| failure_mode: FM-002 | |
| conclude_FM003: | |
| diagnosis: "HP seal blowby — gradual degradation" | |
| confidence: "moderate" | |
| failure_mode: FM-003 | |
| conclude_FM007: | |
| diagnosis: "Insufficient subcooling — two-phase inlet" | |
| confidence: "high" | |
| failure_mode: FM-007 | |
| - id: RC-002 | |
| name: "Pressure Oscillation Diagnostic" | |
| trigger: "PT130 showing high-frequency oscillations" | |
| related_failure_modes: [FM-004] | |
| steps: | |
| - step: 1 | |
| action: "query_sensor_data" | |
| description: "Pull PT130 at 1-second resolution for oscillation analysis" | |
| parameters: | |
| tagindices: [18, 1] | |
| resolution: "1sec" | |
| look_for: "Oscillation frequency and amplitude" | |
| - step: 2 | |
| action: "Correlate with AOV141 cycling" | |
| description: "Check if AOV140/141 is cycling in sync with PT130" | |
| look_for: "Phase correlation between pressure and valve" | |
| next: | |
| if_correlated: "conclude_FM004" | |
| if_not_correlated: "step_3" | |
| - step: 3 | |
| action: "Check DCV dynamics" | |
| description: "Analyze stroke timing — DCV may be bouncing" | |
| look_for: "DCV open/close timing anomalies" | |
| next: | |
| default: "conclude_valve_dynamics" | |
| conclusions: | |
| conclude_FM004: | |
| diagnosis: "Safety loop oscillation — AOV141 hunting" | |
| confidence: "high" | |
| failure_mode: FM-004 | |
| conclude_valve_dynamics: | |
| diagnosis: "DCV dynamic behavior anomaly — investigate spring force" | |
| confidence: "moderate" | |
| failure_mode: FM-002 | |
| - id: RC-003 | |
| name: "Elevated Discharge Temperature Diagnostic" | |
| trigger: "TT130 higher than isentropic prediction" | |
| related_failure_modes: [FM-005, FM-006] | |
| steps: | |
| - step: 1 | |
| action: "query_sensor_data" | |
| description: "Pull TT130, PT130, PT110, TT110" | |
| parameters: | |
| tagindices: [27, 18, 17, 24] | |
| look_for: "TT130 excess above isentropic prediction" | |
| - step: 2 | |
| action: "run_simulation" | |
| description: "Compute isentropic discharge temperature" | |
| look_for: "Measured TT130 vs predicted" | |
| next: | |
| if_excess_gt_20K: "step_3" | |
| if_excess_lt_20K: "conclude_normal_friction" | |
| - step: 3 | |
| action: "Check pressure ratio" | |
| description: "PT130/PT110 ratio vs expected" | |
| look_for: "Is pressure building normally?" | |
| next: | |
| if_ratio_low: "conclude_FM005" | |
| if_ratio_normal: "step_4" | |
| - step: 4 | |
| action: "Check TT110 trend" | |
| description: "Is TT110 rising during operation?" | |
| look_for: "TT110 rate of change" | |
| next: | |
| if_tt110_rising: "conclude_FM006" | |
| if_tt110_stable: "conclude_friction" | |
| conclusions: | |
| conclude_FM005: | |
| diagnosis: "Dry running — pump compressing gas" | |
| confidence: "high" | |
| failure_mode: FM-005 | |
| conclude_FM006: | |
| diagnosis: "ICV thermal backflow — hot fluid heating inlet" | |
| confidence: "high" | |
| failure_mode: FM-006 | |
| conclude_normal_friction: | |
| diagnosis: "Normal — friction heating within expected range" | |
| confidence: "high" | |
| conclude_friction: | |
| diagnosis: "Elevated friction — possible seal break-in or bore damage" | |
| confidence: "moderate" | |
| failure_mode: FM-003 | |
| - id: RC-004 | |
| name: "Reduced Flow Rate Diagnostic" | |
| trigger: "FT140 below expected mass flow rate" | |
| related_failure_modes: [FM-001, FM-002, FM-007] | |
| steps: | |
| - step: 1 | |
| action: "query_sensor_data" | |
| description: "Pull FT140, PT130, VFD speed" | |
| parameters: | |
| tagindices: [7, 18, 13] | |
| look_for: "Flow rate vs expected at current speed" | |
| - step: 2 | |
| action: "Check FT140 calibration" | |
| description: "Verify FT140 density correction factor is applied" | |
| look_for: "Is fluid H2 or N2? Apply correct density correction" | |
| next: | |
| if_calibration_wrong: "conclude_calibration_error" | |
| if_calibration_correct: "step_3" | |
| - step: 3 | |
| action: "run_simulation" | |
| description: "Compute expected flow at current conditions" | |
| look_for: "Vol efficiency and loss breakdown" | |
| next: | |
| if_icv_leak_dominant: "conclude_FM001" | |
| if_dcv_leak_dominant: "conclude_FM002" | |
| if_gas_inlet: "conclude_FM007" | |
| conclusions: | |
| conclude_FM001: | |
| diagnosis: "ICV leakage reducing effective displacement" | |
| confidence: "high" | |
| failure_mode: FM-001 | |
| conclude_FM002: | |
| diagnosis: "DCV leakage losing compressed fluid" | |
| confidence: "high" | |
| failure_mode: FM-002 | |
| conclude_FM007: | |
| diagnosis: "Two-phase inlet reducing effective displacement" | |
| confidence: "high" | |
| failure_mode: FM-007 | |
| conclude_calibration_error: | |
| diagnosis: "FT140 reading incorrect — apply density correction" | |
| confidence: "high" | |
| - id: RC-005 | |
| name: "Motor Power Anomaly Diagnostic" | |
| trigger: "Motor power or current anomaly at given speed" | |
| related_failure_modes: [FM-003] | |
| steps: | |
| - step: 1 | |
| action: "query_sensor_data" | |
| description: "Pull VFD power, current, speed, torque" | |
| parameters: | |
| tagindices: [43, 45, 13, 48] | |
| look_for: "Power/current at each speed point" | |
| - step: 2 | |
| action: "Compare to baseline power-speed curve" | |
| description: "Plot power vs speed, compare to reference" | |
| look_for: "Offset direction" | |
| next: | |
| if_power_higher: "step_3" | |
| if_power_lower: "conclude_reduced_load" | |
| - step: 3 | |
| action: "search_domain_knowledge" | |
| description: "Check seal friction baseline expectations" | |
| parameters: | |
| category: "operational_context" | |
| look_for: "Post-maintenance friction expectations" | |
| next: | |
| if_recent_seal_work: "conclude_seal_break_in" | |
| if_no_recent_work: "conclude_FM003" | |
| conclusions: | |
| conclude_FM003: | |
| diagnosis: "HP seal friction increasing — possible bore damage" | |
| confidence: "moderate" | |
| failure_mode: FM-003 | |
| conclude_seal_break_in: | |
| diagnosis: "Normal seal break-in after maintenance (7-9 kgf → 4-5 kgf)" | |
| confidence: "high" | |
| conclude_reduced_load: | |
| diagnosis: "Reduced load — possible liquid starvation or low discharge pressure" | |
| confidence: "moderate" | |
| - id: RC-006 | |
| name: "Post-Maintenance Performance Verification" | |
| trigger: "Performance check after maintenance event" | |
| related_failure_modes: [FM-001, FM-002, FM-003] | |
| steps: | |
| - step: 1 | |
| action: "search_domain_knowledge" | |
| description: "Look up the maintenance event details" | |
| parameters: | |
| category: "maintenance_history" | |
| look_for: "What was done, what to expect" | |
| - step: 2 | |
| action: "query_sensor_data" | |
| description: "Pull first test run after maintenance" | |
| look_for: "Compare to pre-maintenance baseline" | |
| - step: 3 | |
| action: "run_diagnostics" | |
| description: "Run full D1-D8 diagnostic sweep" | |
| look_for: "Any new or resolved diagnostic flags" | |
| - step: 4 | |
| action: "run_simulation" | |
| description: "Compare sim prediction to post-maintenance performance" | |
| look_for: "Has the residual changed after maintenance?" | |
| conclusions: | |
| conclude_improved: | |
| diagnosis: "Maintenance successfully addressed the issue" | |
| confidence: "high" | |
| conclude_no_change: | |
| diagnosis: "Maintenance did not resolve the underlying issue" | |
| confidence: "moderate" | |
| conclude_degraded: | |
| diagnosis: "Performance worse after maintenance — investigate installation" | |
| confidence: "high" | |