Case Studies - Precognize

Chemical

Flame Retardant Plant Prevents Drop in Product Quality Due to Faulty Temperature Indicator

Problem A faulty temperature indicator led to non-uniform furnace temperatures How SAM...

Chemical

Flame Retardant Plant Prevents Production Loss Due to Poor Pump Performance

Problem A redundant cooling agent pump had mechanical problems, causing reflux temperature...

Chemical

Chemical Plant Prevents Sudden Evaporator Failure

Problem Leakage within a tank that was not easily accessible or visible...

Chemical

Data Showed Control Valve Failure Where Visual Inspection Did Not

Problem Control Valve Failure (fertilizer industry) Issue reported with SAM GUARD® •SAM...

Chemical

Production Failure Prevented When Stirrer Displaced

Problem Stirrer Failure in Reactor (fertilizer industry) Issue reported with SAM GUARD®...

Chemical

Critical Pump Failure Prevented in Fertilizer Plant

Problem Pump failure, inlet flow to distillation column in a fertilizer plant....

Petrochemical

Continuous Discrepancy in a Relationship Between Vibration Tags

Problem SAM GUARD identified a continuous discrepancy in a relationship between two...

Plastic

Tank Level Meter Faulty in Plastics Plant

Problem The meter measuring the level of polymer plastic in the tank...

Petrochemical

Petrochemical Plant Prevents Damage Due to Faulty Valve

Problem A particular valve was behaving strangely One valve was constantly closed,...

Petrochemical

Control Room Running Blind to Compressor’s Status

Problem The translator for the signals from the controller responsible for the...

Petrochemical

Fixing Wear & Tear on Valve to Regain Control Over Flow

Problem A valve was not closing properly, which led to a lack...

Chemical

Chemical Plant Fixes Reactor’s Pump to Maintain Batch Quality and Quantity

Problem Failure in the reactor’s jacket pump, which circulates the flow inside...

Chemical

Early Alerts Prevented Product Loss

Problem Leakage in the heat exchanger – outlet temperature is higher than...

Petrochemical

Flare Event and Communication Crisis Prevented

Problem Pressure difference was growing for control valve. How SAM GUARD Helped...

Mining

Vibration Drift in Pump

Problem The pump was experiencing vibration drift: There was an observable change...

Mining

Oil Temperature Rise in Pump

Problem The pump’s oil temperature rose by >10[C]. This temperature level is...

Chemical

Blockages in Furnace

Problem The plant was experiencing blockages. Faulty product temperature reading may have...

Pulp & Paper

Boiler Motor Failure

Problem Boiler motor failure How SAM GUARD Helped A failure that happened...

Chemical

Chemical Plant

Problem Customer complained of availability issues. Operation was not smooth, and availability...

Cement

Broken Tooth in Raw Mill Separator

Problem One of the plant’s raw mill dynamic separators had a broken...

Petrochemical

Non-repeating Failures in Different Locations

Challenges Plant has non-repeating failures that occur in a different location each...

Refinery

Beating the Fixed Alarm Threshold

Problem Indicators showed position tags of valve at 90%. Reformer tube temperature...

Chemical

Blockage in Heat Exchanger

Problem Partial blockage led to reduced heat transfer, potentially higher energy costs,...

Cement

Failures in Overlooked and Ignored Places in Plant

Challenges Need to increase visibility within the plant. Failures occur in overlooked...

Pharmaceutical

Probe Failure in Fermenter

Problem •A probe is used in a fermenter to detect various process...

Pharmaceutical

Pressure Sensor Failure in Bubble Trap

Problem •SAM GUARD detected a change in set point behavior of flow...

Chemical

Chemical Plant Recalibrates Faulty pH Sensor

Problem Growing deviation between the values of two pH sensors Measurement Tags...