1. Introduction

The first part of this manual explained the process of creating and configuring the Heat and Stress simulation models using the Akselos Reactor Wizards. That stage prepared the structural twin and established the foundation for analysis.

This second part focuses on the Reactor MPT Dashboard, which presents the simulation results from these models in a structured and accessible format. The dashboard consolidates information into visual and numerical outputs that represent the thermal and structural behavior of the reactor under operating conditions.

This guide provides an overview of the dashboard’s main features and pages, detailing the information displayed and how it is organized. It explains the key use cases supported by the dashboard, including monitoring reactor behavior during different operating phases such as startup and shutdown, accessing historical data for long-term condition assessment, and reviewing alternative operating scenarios using available tools to understand their impact on reactor performance.

The document is intended for users who interact with the dashboard. It assumes that the initial model setup and sensor data integration described in Part 1 have been completed, and users already have an MPT Dashboard deployed.

2. Before You Begin

2.1. Akselos Integra

Before using the SPM for Reactors tool, it’s helpful to understand how it fits within the broader Akselos Integra® platform. Integra combines local modeling, cloud computing, and centralized data management to support an efficient simulation workflow. This architecture ensures that users can build, solve, and manage models smoothly across connected tools.

• Akselos Modeler (local desktop application): With a set of Reactors Wizards (plugins) installed, it is used to build the Reactor model, define geometry, materials, and load conditions, define MPT curves and sensor information. It serves as the user interface for model setup and post-processing.
• Akselos Cloud (server back-end): Handles all simulation solving processes. Once models are synced from the local machine, the cloud performs high-speed computations without requiring local resources.
• Akselos Portal (web-based front-end): Used to manage collections, organize simulation jobs, track solve progress, and access shared results. It enables collaboration and centralized data control.

Once the model is built in Modeler, it is synced to the Cloud for solving. The Portal manages these synced collections and jobs, while the final results are returned to the Modeler for visualization or accessed through the Portal for review and documentation.

To ensure a smooth setup and workflow, it’s recommended to complete a few setup steps and review relevant support materials on the Akselos Portal.

Specifically, users should create an Akselos Portal account and ensure access to the necessary workspace and collections. Reference: [Create Akselos Portal Account] – Required to access the platform and use the tool.

2.2. Workflow Overview

The Akselos MPT Assessment is an automated, end-to-end workflow that guides the user from initial setup to live monitoring. The process integrates specialized products (Wizards and a Dashboard) to ensure asset integrity.

Figure 2.1: The Akselos MPT Assessment

As illustrated in the workflow diagram, the process consists of the following stages:

Stage 1 - Model Configuration with Reactor Wizards on Akselos Modeler: This is the initial setup phase, where the user leverages a suite of specialized wizards to build the foundation for the assessment.

• Reactor Model - Load Configuration wizards: Automatically builds the two base simulation models required for the analysis: a Heat Model to simulate thermal behavior and a Stress Model to calculate mechanical stresses.

• Sensor Configuration Wizard: Creates the digital placeholders, or "connection gates," for each physical sensor, preparing the model to receive live data.

• MPT Curves Wizard: Allows the user to define the safety limit curves (MPT curves) for the various material zones within the reactor.

The outcome of this stage is a fully configured pair of simulation models, which are then synchronized to the Akselos Cloud, ready for analysis.

Stage 2 - MPT Assessment and Live Processing: Once configured, the models are utilized by the MPT Assessment Applets running on the Akselos Cloud platform.

These applets automatically stream live sensor data from the plant's database and perform the thermo-mechanical analysis in near real-time to calculate the temperature distribution and stress state across the entire reactor.

The process supports both Live Processing for operational monitoring and Manual Processing for "what-if" scenarios using hypothetical data.

Stage 3 - Visualization on the MPT Dashboard: This is the final, operator-facing product where the results from the MPT Assessment Applets are visualized.

Figure 2.2: The Akselos MPT Dashboard

• The MPT Dashboard provides a clear, intuitive view of the reactor's status through live monitoring charts and key performance indicators like the Utilization Factor.

• It enables operators to make proactive decisions to optimize heat-up and cool-down rates, safely reduce downtime, and explore the results of what-if scenarios.

This document focuses on the Reactor MPT Dashboard, the primary interface for monitoring the structural health and operational performance of reactor assets. This guide is intended for users who are moving into the operational monitoring phase (Stage 2), and it assumes that the initial model setup, configuration, and data connections have already been completed.

The starting point for this guide is a fully configured and operational MPT Dashboard. We will walk through its various features and pages, explaining how to interpret the data and use the available tools for real-time monitoring, historical analysis, and predictive simulation.

3. Reactors Operation monitoring with Akselos Dashboard

The Akselos MPT Dashboard is the last stage of the Structural Performance Management (SPM) workflow. It transforms complex engineering data into a clear, interactive interface, enabling real-time monitoring and proactive decision-making to ensure the safe and efficient operation of reactor assets.

Within the Akselos Portal, the entire data ecosystem for an engineering assessment is organized into Collections. These function as a centralized data repository, containing the core entities of the data model, including geometric models, mesh files, loading conditions, and sensor inputs. The final, processed results and visualizations are then published to an AKSELOS Dashboard Report, which serves as the interactive analytics interface.

Figure 3.1: Hydrocracking Reactor Dashboard on AKSELOS Portal.

The Dashboard Report is the primary environment for interacting with and interpreting the analysis findings.

3.1. Common Interface Features

The MPT Dashboard includes several built-in interactive features designed to improve navigation, data review, and visualization clarity. These features allow users to enlarge visuals for detailed inspection, export underlying data for offline review, and apply filters to focus on specific information. The following sections explain how to use these capabilities effectively. While the dashboard provides a broad range of tools, this guide focuses on the core functions commonly used in day-to-day interactions. 

Focus Mode

Focus Mode expands a selected visual, such as a chart or table, to occupy the full dashboard canvas. This feature is particularly useful for examining complex datasets, reviewing detailed labels, and analyzing trends without distractions from other visuals. It is also valuable during technical reviews or presentations where a single visual needs emphasis.

Figure 3.2: Focus Mode pop-up button.

How to activate Focus Mode:

Step 1: Hover the mouse over the top-right corner of the visual you want to enlarge. A small menu will appear.

Step 2: Select the Focus Mode icon.

Step 3: The visual expands to full-screen view for easier inspection.

Step 4: To return to the standard dashboard view, click the Back to report button in the top-left corner.

Exporting Data from Tables and Charts

The dashboard allows exporting the underlying data from visuals into a local file. This capability supports offline analysis, custom reporting, and integration with other analytical tools. Exported data reflects the current state of the visual, including any filters applied.

Figure 3.3: Export data.

How to export data:

Step 1: Hover over the top-right corner of the chart or table you want to export. A menu will appear.

Step 2: Select the More options icon (three dots).

Step 3: From the dropdown, select Export data.

Step 4: In the export window:

1. Choose Summarized data (aggregated values such as sums, averages, or counts used in the visual).
2. Select the file format (default is .xlsx, which supports up to 150,000 rows).
   
3. Click Export to download the file.

Note: Exporting detailed underlying data is disabled to maintain performance and confidentiality.

Extra Functionality

There is some extra functionality available for this Dashboard, aimed at keeping the user informed of the latest updates and answering any quick questions related to the operation status of the asset. These functions can be found on the top right of any Monitoring page and are accessible by clicking the highlighted icons. These are referred to as:

• Questions and Answers
• Latest Notification

Figure 3.4: Message box and Notification.

1. Questions and Answers

For the Question and Answer Functionality, this is intended for users to quickly obtain information from the Dashboard without having to specifically navigate to the corresponding page. Users can utilize the question based information gathering system of the Dashboard.

Figure 3.6: Message box navigation

To access this functionality, click on the Message Box on the top right corner of any monitoring page. A new window will pop up, allowing users to ask the frequently asked questions on the Dashboard Report.

Figure 3.7: Message box usage

1. Frequently asked questions: This section contains questions that are frequently asked. Users can use these if they match their query to save time inputting the question.

2. Answer to requested query: Once the question has been inputted, it will be processed, and the answer/result that best fits the query will be displayed here.

2. Notification

The Dashboard is designed to deliver information to users in the most efficient and effective formats, through charts, figures, and interactive elements. But if users need to be updated with specific key information at a glance, the Notification System can be set-up to accommodate this.

Figure 3.8: Notification navigation

In this case, the Notification is set-up to update whenever there is a change in Max Utilization Factor, and in which zone it occurred. To view this, users can hover over the Bell icon to view the latest updates table.

3.2. Home Page

The Home page serves as the executive summary dashboard, providing a high-level of the asset's identity and core parameters.

Equipment Data Table

This table visual provides a consolidated view of the asset's fundamental attributes, including its operational status, key physical specifications, design operating conditions, cumulative operational history, and material properties.

Figure 3.9: Equipment data interface

Equipment Data Card: This table presents a consolidated view of the asset’s fundamental attributes. The details are defined within the model; refer to User Manual Part 1: HCU Reactor – Automation Wizards for more information. 

3.3. SPM Monitoring

MPT Monitoring - Main Page

This page is the primary real-time operational dashboard, designed for live monitoring of the asset's structural integrity against predefined MPT limits.

Figure 3.10: SMP Monitoring - MPT monitoring page

1. Key Performance Indicators (KPIs): This section provides a quick summary of the most important indicators calculated from the latest available data in the MPT Dashboard:

• Max. Utilization: Displays the highest MPT Utilization Factor (UF) among all zones or Stress Classification Line ( SCL) paths at the latest timestamp. The UF represents the ratio of the current maximum principal stress to the allowable stress at the current temperature, as defined by the assigned MPT curve. A value of 1.0 (or 100%) means the calculated stress has reached the allowable limit.

• Max. Location: Identifies the specific zone or SCL path where the maximum Utilization Factor occurs. This helps users quickly locate the most critical area for review.

• Since Last Update: Shows the exact timestamp of the most recent data update and the elapsed time since that update. If the elapsed time exceeds the predefined threshold (time limit), the indicator will trigger an alert. This serves as a data freshness check to confirm whether the displayed information is current or if new data is overdue.

2. Sensors Data: This chart plots real-time temperature and pressure readings streamed directly from the sensors installed on the asset and stored in the Akselos database. While this data serves as a critical input for the simulation model to perform the MPT assessment and to calculate the heat-up/cooldown rate, its purpose on the dashboard is also for direct operational monitoring. Displaying the raw sensor data allows operators to visually track live conditions, verify data integrity against the plant's control system.

3. MPT of Max Location: This chart displays the MPT curve for the zone or SCL path with the highest Utilization Factor (UF) at the latest timestamp, which helps confirm whether the latest operating condition for the most critical location stays within the defined MPT limits. It serves as a critical reference by showing:

• Allowable Stress vs. Temperature Curve (Blue Line): Represents the MPT limit curve defined for the selected zone, indicating the allowable stress for different temperatures.
  
• Evaluation Stress Points (Green): Calculated stress values at previous timestamps for this zone or SCL path.
• Latest Evaluation Stress (Orange): The most recent stress and temperature point where the maximum UF was recorded.

4. Heatup/Cooldown rate: This chart tracks the rate of temperature change (°C/hr) over time, which is calculated as the change in temperature over a specific time interval using sensor data. This rate is a critical parameter for managing thermal stresses during transient operations like startup and shutdown.

The basic rate is calculated using the two most recent sensor data intervals with the following formula:

Rate = (Current Temperature - Previous Temperature) / (Time Interval)

After this value is calculated, if the (Time Interval) is not 1 hour, it will be converted into °C/hr and then uploaded to the Dashboard Report.

For example, if a sensor reads:

• Current Temperature (T₂): 360°C at 9:30 AM

• Previous Temperature (T₁): 330°C at 9:00 AM

The calculation would be:

• Rate = (360°C - 330°C) / 30 minutes = +1°C/minute

Which will be converted to +60°C/hr on the Dashboard for that time interval.

5. Historical Utilization of Zones (Trend Analysis)

This visualization shows the historical trend of the Utilization Factor (UF) for multiple MPT zones and Stress Classification Line (SCL) paths. The UF is expressed as a percentage, where 100% corresponds to reaching the allowable stress limit defined by the MPT curve. 

• X-Axis: Time (latest timestamps on the right).

• Y-Axis: UF percentage for each zone or SCL path.

• Legend: Displays all zones and SCL paths (e.g., mpt_nozzle, mpt_shell, SCL Nozzle1). Each line represents the UF trend for that region over time.

• Interaction: Hover over the chart to view exact UF values at specific timestamps. Use the slider at the bottom to zoom into a time range for detailed inspection.

This feature provides a comparative view of utilization behavior across multiple regions, helping to verify the consistency of model performance and identify any anomalies across zones and SCL paths during the analysis period.

6. Solution Views: This feature displays simulation results statically on the model of the reactor. The contour plot uses a color gradient to indicate variations in values such as temperature, maximum principal stress, or Utilization Factor (UF), helping to quickly identify areas of interest or concern.

Users can:

• Select the parameter to display from the dropdown menu (e.g., Temperature, Stress, Utilization).
• Change the viewing angle (XY, XZ, YZ, or Isometric) to inspect different parts of the model.
• Check detailed numeric values for critical zones and Stress Classification Lines (SCLs) listed alongside the model, including allowable stress, evaluation stress, and UF.

This visualization complements charts and tables by showing where high stresses or critical utilization values occur on the reactor. It is particularly useful for verifying that the system behavior aligns with expected patterns, such as heat concentration near process zones or stress concentration at nozzles and welds.

MPT Monitoring - Additional Locations

If users wish to inspect the Utilization Factor of other zones, there is an additional page, which is accessible by clicking the button within the MPT of Max Location Panel.

Figure 3.11: MPT monitoring - main page - MPT of Max. Location

Accessing this page will present the user with all the available MPT Monitoring Zones, where the historic and current values can be inspected and evaluated.

Figure 3.12: all zones' mpt chart

1. Time Range and Page Selection: Users can use the Time Range Selector to filter into specific time ranges. The Page Selector is used to view the MPT Utilization Factor charts of the Zones later on the list (six curves can be viewed at a time).

2. MPT of Zones: This is where the MPT value of each Zone is presented, users can use this section to compare the values from different Zones as it still contains the key MPT reference values:

• Allowable Stress vs. Temperature Curve (Blue Line): Represents the MPT limit curve defined for the selected zone, indicating the allowable stress for different temperatures.

• Evaluation Stress Points (Green): Calculated stress values at previous timestamps for this zone or SCL path.

• Latest Evaluation Stress (Orange): The most recent stress and temperature point where the maximum UF was recorded.

3.4. Process Monitoring

This page offers a comprehensive view of the process data ingested into the system, focusing on long-term trends rather than single-point readings. While the MPT Monitoring page highlights sensor values at a specific moment in the latest cycle, this section presents historical data across a broader time range. It enables users to observe patterns in temperature and pressure evolution, supporting the validation of input consistency and identifying any irregularities in the sensor data.

Figure 3.13: Process monitoring page

1. Sensor Data and Heat Up/Cool Down Rate: These charts are consistent with the ones introduced earlier.

2. Time Range Slicer (Top Panel): The slicer at the top allows users to define the period of interest. All charts on this page are linked to this selection and will automatically update to reflect the chosen time range, enabling consistent and comparative analysis.

3. Sensor Location (Right Panel): A 3D schematic showing the relative position of each sensor on the reactor model. It helps users understand the context of each data point, evaluate whether the readings align with expected behavior, and perform any necessary verification based on sensor placement.

3.5. Asset Integrity

This section enables in-depth engineering evaluation by exposing detailed stress and utilization results across all defined MPT curves and structural zones. It helps engineers investigate stress behavior beyond the maximum value shown in the SPM Monitoring view by displaying Utilization Factors for all MPT locations and providing stress trends over time for each Stress Classification Line (SCL) or a specific zone.

MPT Tracking

This page delivers a structural integrity assessment of the asset using both live and historical sensor data. By integrating engineering analysis with real-time input, it helps monitor the asset’s condition, detect abnormal behaviors, and support safe operation.

KPI Cards

Summarizes the most critical live metrics for this diagnostic view: Max. Utilization, the Max. Location, and the Last Update timestamp.

Figure 3.14: Asset Integrity - MPT tracking page

Data Visualization Panels

1. Sensors Data: 

This chart presents historical sensor readings over a defined time range. When users select a period, the displayed values reflect sensor history, making it possible to cross-check with corresponding MPT evaluation results shown on the right.

2. Historical Utilization: This time-series chart tracks the Utilization Factor of each MPT location throughout the selected time range. It is useful for identifying how utilization changes across operating cycles and validating whether stress levels recorded in previous MPT charts align with sensor and process conditions.

3. MPT Stress vs. Temperature: While the SPM Monitoring page shows only the curve of the most critical MPT at a given time, this section displays all relevant MPT charts side by side for full comparison. Each scatter plot represents a critical point defined in the model (e.g., mpt_nozzle, mpt_shell), allowing engineers to assess whether any zone consistently experiences higher stress than others.

Stress results

This page provides a detailed view of the asset’s stress condition to support root cause analysis and investigation of high-stress regions.

Figure 3.15: Asset Integrity - Stress Results page

1. KPI Cards: These cards summarize the current maximum stress and its location, giving engineers a quick indication of the most critical area at the selected time range.

2. Sensor data and Heat up/cool down rate: This panel remains consistent with previous pages, showing temperature and pressure sensor trends over time to provide process context for the stress analysis.

Main Analysis Panels:

3. Each Location Detailed Results: This interactive table presents the Von Mises Stress and Utilization Factor for all critical zones (e.g., mpt_weld, mpt_shell, scl welds).

• Selecting a row filters the rest of the page accordingly.

• This interaction ensures that only data for the selected component is displayed in the static model and historical chart, helping users focus their investigation on a specific region.

4. Historical Stress of Selected Zone: This chart plots how stress evolves over time for the selected zone or SCL. It provides multiple stress components to help identify the source and severity of the stress:

• Von Mises Stress

• Membrane Stress

• Bending Stress

• Peak Stress

• Principal Stress

5. Solution View: Solution View: An static model that visually maps the stress distribution across the entire asset, with a color legend to quantify stress levels and identify hotspots.

3.6. Advanced Analysis

What-if simulation

This section supports engineering evaluation by allowing users to define hypothetical sensor data and simulate reactor behaviors under those conditions. It is designed for proactive and predictive asset management, enabling users to model the impact of alternative operating scenarios without affecting the actual process. This capability is essential for data-driven planning, risk assessment, and process optimization.

The key difference from the SPM Monitoring page is the data source. While the SPM page displays results based on live sensor inputs, the What-If Simulations page is powered by user-defined scenarios uploaded via the MPT - What-If Analyzer applet. Although the interface remains largely similar, all plots and results are based on the simulated data provided by the user.

Note: The term applet refers to a lightweight tool developed by Akselos and deployed on the platform’s portal. Each applet is designed to perform a specific task within the workflow. In this case, the MPT - What-If Analyzer applet is responsible for running the MPT assessment based on the hypothetical sensor data uploaded by the user.

Workflow for What-if Analysis

To run a what-if analysis, users must first create a scenario file, upload it using the applet, and then view the results on the dashboard.

1. Prepare the Scenario Data File

The analysis requires a specific data format. A template is provided to ensure the data is structured correctly.

Figure 3.16: sample sensor data

• Download the Template: users can find the template in the attached file.
• Populate the Template: Open the .csv file. It will contain columns for Datetime and a series of sensor tags (e.g., tag00000, tag00001, etc.). Populate this file with a time-series of hypothetical data representing the scenario you wish to model. For example, to simulate a faster startup, you would define a series of temperature and pressure values that represent a more aggressive heat-up and pressurization ramp.

2. Upload and Run the Scenario

Once the data file is prepared, you can upload it to the applet to run the simulation.

Figure 3.17: MPT - What-if Anyalyzer applet

• Name the Scenario: In the Scenario Name field, enter a descriptive name for the analysis (e.g., "Scenario 1 - July 2025").
• Upload the File: Click the Upload File(s) button and select the completed .csv file.
• Run the Analysis: Click the Run MPT - What-If Analyzer button to start the simulation. The applet will process the data, run the MPT assessment using the hypothetical inputs, and save the results under the scenario name you provided.

3. View the Scenario Results on the Dashboard

After the applet has finished processing, the results will be available for analysis on the dashboard.

Figure 3.18: Advanced Analytics - What-if Simulations page

• Navigate to the Advanced Analytics tab on the main dashboard.
• Click the Scenario Selection dropdown menu. The newly created scenario will appear in the list.
• Select the scenario. All visuals on the page will update to display the predicted outcome of that simulation, allowing for a direct comparison of the forecasted results against established safety limits.
• On the page to display the predicted outcome of that simulation, allowing for a direct comparison of the forecasted results against established safety limits.

4. Final thoughts

Thank you for using the Structural Performance Management for Reactor User Manual. We hope this guide has provided clear instructions and helpful context for setting up, solving, and assessing the Reactor models with confidence. If you encounter any issues or have additional questions, please don’t hesitate to reach out to our support team at [email protected]. We are here to assist you in ensuring a smooth and accurate simulation experience. For updates, training resources, or to provide feedback, please visit the Akselos Portal or contact the account representative directly.