INJ-00019 — mac_efficiency_loss
Status: EXPIRED · Category: A · Source: auto Fired at: 77.62 h · Duration: 8.0 h · Target: NE-01 Economic impact: $-60 /h
Parameters
{
"eff_loss_pct": 3,
"plant_id": "NE-01",
"product": "LOX",
"customer_id": "C-19",
"truck_id": "T-E05",
"driver_id": "D-E04"
}Cascade — 10 agent steps
| # | step | agent | detail |
|---|---|---|---|
| 1 | INJECTION | Injection Engine | mac_efficiency_loss: MAC isentropic efficiency degraded. Same load now draws more power. Health dropped to 88%. |
| 2 | MPC_SOLVE | MPC Optimizer | 📐 MPC: Optimal load 73% (4h horizon) | Priority: 3 | Expected margin: $0/h | Reason: All constraints healthy → optimize revenue (+load) |
| 3 | PHYSICS | Physics Kernel | MAC efficiency drop means more electricity per kg of air compressed. At 79% load, power draw increased ~20% above design. Suspect: fouled inter-stage cooler, worn labyrinth seals, or impeller erosion. Discharge temper… |
| 4 | PRODUCTION | Production Agent | Reducing 79%→71% lowers power draw proportionally. At 71%, GOX/GAN/LOX/LIN production drops ~10%. Power savings: 1.7MW × 55/h. |
| 5 | TANKS | Tank Inventory Agent | Lower production → tanks drain toward demand baseline. LOX at 60%, LIN at 61%. Fill rates drop ~10%. If maintenance takes >4h, tank levels may approach critical. |
| 6 | DISPATCH | Dispatch Agent | Normal dispatch continues. No emergency needed unless tank levels drop below 25%. Monitor LOX and LIN fill rates for early warning. |
| 7 | CUSTOMERS | Customer Impact Agent | Short-term: no customer impact. Medium-term (>6h at 71%): customers with <3 days inventory may need priority dispatch. Product quality unaffected — efficiency loss is thermodynamic, not separation quality. |
| 8 | LOSS_MITIGATION | Loss Ledger | 📉 L1: Primary Production Physical Balance — PROC optimizes load to maintain accurate production metering |
| 9 | ECONOMICS | Economics Agent | At 79% with degraded efficiency: power cost +55/h. Revenue loss from reduced production: -$30/h. NET: maintenance pays for itself in 91h. |
| 10 | RECOVERY | Recovery Planner | 1) MAC inspection crew dispatched. 2) Root cause: seal wear, fouling, or bearing degradation. 3) Repair 4-8h depending on cause. 4) Post-maintenance: efficiency returns to 84% design point. 5) Ramp load back to 79% an… |
Raw effects
- MAC eff 81%, health 97%
- mac_efficiency_loss: MAC isentropic efficiency degraded. Same load now draws more power. Health dropped to 88%.
- 📐 MPC: Optimal load 73% (4h horizon) | Priority: 3 | Expected margin: $0/h | Reason: All constraints healthy → optimize revenue (+load)
- MAC efficiency drop means more electricity per kg of air compressed. At 79% load, power draw increased ~20% above design. Suspect: fouled inter-stage cooler, worn labyrinth seals, or impeller erosion. Discharge temperature elevated.
- Reducing 79%→71% lowers power draw proportionally. At 71%, GOX/GAN/LOX/LIN production drops ~10%. Power savings: 1.7MW × 55/h.
- Lower production → tanks drain toward demand baseline. LOX at 60%, LIN at 61%. Fill rates drop ~10%. If maintenance takes >4h, tank levels may approach critical.
- Normal dispatch continues. No emergency needed unless tank levels drop below 25%. Monitor LOX and LIN fill rates for early warning.
- Short-term: no customer impact. Medium-term (>6h at 71%): customers with <3 days inventory may need priority dispatch. Product quality unaffected — efficiency loss is thermodynamic, not separation quality.
- 📉 L1: Primary Production Physical Balance — PROC optimizes load to maintain accurate production metering
- At 79% with degraded efficiency: power cost +55/h. Revenue loss from reduced production: -$30/h. NET: maintenance pays for itself in 91h.
-
- MAC inspection crew dispatched. 2) Root cause: seal wear, fouling, or bearing degradation. 3) Repair 4-8h depending on cause. 4) Post-maintenance: efficiency returns to 84% design point. 5) Ramp load back to 79% and monitor power draw for confirmation.