Problem

•SAM GUARD detected a change in set point behavior of flow controller with frequent step changes.

•This was followed by an alert at the pressure sensor located on the bubble trap reporting a constant value.

•The pressure sensor which is in cascade with the pump, provides control values to the flow & temperature valves which regulate the process parameter of various equipment parts. •

Impact

The required parameters to start the regeneration phase were not reached due to the defective sensor. Since the regeneration phase did not begin, the process was stopped. •

Conclusion

Although SAM GUARD gave earlier warnings, it was discovered on site only on 31/03 almost 30 days after the initial alert causing major issues in production. •

Value

SAM GUARD provided early alerts and rapid detection of the pressure problem. Production loss could have been prevented if the alerts had been considered when surfaced.