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Predictive analytics for the process industry

The SAM GUARD® predictive analytics solution for the process industry quickly and accurately identifies equipment failures and suspicious operating modes days to weeks in advance. It provides an average of five early, accurate and actionable alerts a day.

SAM GUARD combines artificial intelligence (AI) with human intelligence (HI) in the form of plant know-how (human-enhanced machine learning) to achieve maximum availability, performance and productivity.

The most important features and functions at a glance

Coverage of the entire plant

With SAM GUARD, you can keep track of the entire plant. SAM GUARD detects failures in rotating and static equipment as well as deviations in operating modes and process behavior.

It's in your hands

Alerts are clear and point to the exact location and nature of failure. Your team is able to act on the alerts and no data science knowledge is needed.

Your knowledge counts

Industrial assets require a specific approach. SAM GUARD combines your expert know-how with machine learning (ML) to achieve a unique predictive monitoring solution.

No alert fatigue

Don't waste time on false alarms. Instead of indicating hundreds of anomalies, SAM GUARD issues no more than five truly actionable alerts a day.

No surprises

Get notified of a failure 3 weeks to a few hours in advance. No more surprises in the middle of the night. Planned, proactive maintenance saves you money.

Quick start-up

Your data and sensor values are already available. It takes only one to two weeks for your process engineers to specify the plant structure and behavior in the software - and SAM GUARD is up and running.

Related publications

Predictive Analytics for the Process Industry

SAM GUARD demo version

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OVERVIEW

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SAM GUARD enables you to …

Detect equipment failures ahead of time
Analyze the root causes of anomalies
Identify suspicious process behavior
Identify deviating operating modes

Covers the entire plant

With few historical events and the interconnectedness of process plants, you never know where the next failure will occur. With SAM GUARD, there is no need to select what to monitor, you can simply keep track of everything.

No alert fatigue

Instead of hundreds of alerts per day, SAM GUARD generates up to five alerts, giving you early, actionable warning.

Two-week implementation

With a swift implementation process and no additional hardware required, SAM GUARD is up and running quickly, analyzing your plant data and predicting failures.

No data scientists needed

SAM GUARD alerts are analyzed by your plant’s operating staff, with no specialized data analysis know-how needed.

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Increase your plant´s availability, performance and production now

Data migration

You already invested in the collection of your data? Then benefit from it now.

In most plants, sensor data are already being collected in a data historian. SAM GUARD enables you to leverage this investment and maximize your knowledge based on the existing data.

Supported data historians

OSISoft PI
Aspen PIMS™
IBA
Siemens, GE

Available integration methods

File transfer
SQL
Web
API

Implementation

SAM GUARD works on-premises, i.e. in your corporate network. The software can be installed on any virtual machine running Linux. Space can be provided on our SAMSON and Precognize servers free of charge or the application is installed on your own servers.

Make your own choice.

Operation

Users: process engineers, control room technicians, maintenance engineers, production managers and shift leaders
Access: SaaS (Software-as-a-Service) using a web browser
Frequency of access: usually once or twice a day
Notifications: by SMS text message or e-mail, by push notification using your company's notification system (with annual subscription only)

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Case studies

More case studies on www.precog.co.

Case studies

4 % efficiency increase

Chemical plant: availability

Customer recounts of availability issues. Operation is not smooth and availability is lower than expected

Thanks to SAM GUARD, unplanned plant downtime was reduced from 14 % to 10 %. A substantial increase of 4 % was measured in the overall plant availability.

» Go to case study

Damage of US$ 734,000 prevented

Petrochemical plant: compressor

Non-repeating failures in a plant, each time a different failure occurs in a different location
Improve overview of the entire plant. The failures occurred in overlooked and ignored parts of the plant.

SAM GUARD's alerts prevented the failure of the compressor used in the system that supplies compressed air to the valves of the entire plant. A compressor failure would have shut down the entire plant.

» Go to case study

Production loss prevented

Petrochemical plant: heat exchanger

Partial blockage, which led to reduced heat transfer, potentially higher cost of energy and increased flow velocity, which may lead to potential erosion problems

SAM GUARD’s latest feature provides alerts even if direct measurements are impossible.

» Go to case study

Damage of US$ 103,000 prevented

Cement plant: motor fan

Non-repeating failures in a plant, each time a different failure occurs in a different location
Improve overview of the entire plant. The failures occurred in overlooked and ignored parts of the plant.

Overlooked broken dampers were replaced thanks to SAM GUARD’s alerts. A significant damage to the raw mill fan was prevented.

» Go to case study

Major pump failure prevented

Refinery: pump

Indicators showed 90 % valve position at certain tags.
The reformer tube temperature slowly dropped from 785 to 750 °C (low alarm set point: 650 °C).
The reformer draft opening dropped from 98 % to 42 %.

SAM GUARD helped remedy a minor problem at an early stage to prevent a major damage involving plant downtime and production loss.

» Go to case study

1-day production loss prevented

Cement plant: raw mill separator

Broken tooth of dynamic separator in raw mill

SAM GUARD gave pinpointed alerts, directing maintenance staff to the exact separator. The overlooked defective tooth could be replaced. A significant damage to the dynamic separator of the raw mill was prevented.

» Go to case study

Webinars

The Devil is in the Details

Analytical Monitoring for process plants: Integrating analytics into your operations

Predicting Failures in the Process Industry: How to Calculate ROI

Predictive Analytics is here to Scale

Machine Learning: The Truth, the Whole Truth, and Nothing but the Truth

Phone:	+1 281-383-3677
Fax:	+1 281-383-3690