{"id":45863,"date":"2020-09-16T12:54:15","date_gmt":"2020-09-16T19:54:15","guid":{"rendered":"https:\/\/www.cohu.com\/?p=45863"},"modified":"2025-03-28T12:59:02","modified_gmt":"2025-03-28T19:59:02","slug":"risks-and-faults","status":"publish","type":"post","link":"https:\/\/www.cohu.com\/tignis\/so-many-risks-and-faults-at-stake","title":{"rendered":"So Many Risks and Faults at Stake"},"content":{"rendered":"\n<style type=\"text\/css\" data-created_by=\"avia_inline_auto\" id=\"style-css-av-m8g28v5p-746d8baae8d89148fb421ccddfa3a141\">\n.avia-section.av-m8g28v5p-746d8baae8d89148fb421ccddfa3a141 .av-parallax .av-parallax-inner{\nbackground-repeat:no-repeat;\nbackground-image:url(\/wp-content\/uploads\/2025\/03\/resources-banner-1500x333.jpg);\nbackground-position:50% 50%;\nbackground-attachment:scroll;\n}\n.avia-section.av-m8g28v5p-746d8baae8d89148fb421ccddfa3a141 .av-section-color-overlay{\nopacity:0.3;\nbackground-color:#000000;\n}\n<\/style>\n<div id='av_section_1'  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.av-subheading{\nfont-size:15px;\n}\n}\n<\/style>\n<div  class='av-special-heading av-m8g29ww6-eae5135b0895c3f76a92dcd7e248c63a av-special-heading-h1 custom-color-heading blockquote modern-quote  avia-builder-el-2  avia-builder-el-no-sibling  av-inherit-size av-linked-heading'><h1 class='av-special-heading-tag '  itemprop=\"headline\"  >PHYSICS, MACHINES AND DATA<\/h1><div class=\"special-heading-border\"><div class=\"special-heading-inner-border\"><\/div><\/div><\/div><\/div>\n<style type=\"text\/css\" data-created_by=\"avia_inline_auto\" id=\"style-css-av-2pyrzd-6af470dabd56f3b979785905ac98eceb\">\n.flex_column.av-2pyrzd-6af470dabd56f3b979785905ac98eceb{\nborder-radius:0px 0px 0px 0px;\npadding:0px 0px 0px 0px;\n}\n<\/style>\n<div  class='flex_column av-2pyrzd-6af470dabd56f3b979785905ac98eceb av_one_third  avia-builder-el-3  el_after_av_two_third  avia-builder-el-last  flex_column_div av-zero-column-padding  '     ><style type=\"text\/css\" data-created_by=\"avia_inline_auto\" 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itemprop=\"thumbnailUrl\" srcset=\"\/wp-content\/uploads\/2025\/03\/Tignis-Logo-cohu-tagline-all-white-transparent-300x89.png 300w, \/wp-content\/uploads\/2025\/03\/Tignis-Logo-cohu-tagline-all-white-transparent-1030x305.png 1030w, \/wp-content\/uploads\/2025\/03\/Tignis-Logo-cohu-tagline-all-white-transparent-768x228.png 768w, \/wp-content\/uploads\/2025\/03\/Tignis-Logo-cohu-tagline-all-white-transparent-1536x455.png 1536w, \/wp-content\/uploads\/2025\/03\/Tignis-Logo-cohu-tagline-all-white-transparent-2048x607.png 2048w, \/wp-content\/uploads\/2025\/03\/Tignis-Logo-cohu-tagline-all-white-transparent-1500x444.png 1500w, \/wp-content\/uploads\/2025\/03\/Tignis-Logo-cohu-tagline-all-white-transparent-705x209.png 705w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/><\/div><\/div><\/div><\/div>\n<\/div><\/div><\/main><!-- close content main element --><\/div><\/div><\/div><div id='after_section_1'  class='main_color av_default_container_wrap container_wrap fullsize'  ><div class='container av-section-cont-open' ><div class='template-page content  av-content-full alpha units'><div class='post-entry post-entry-type-page post-entry-45863'><div class='entry-content-wrapper clearfix'>\n<div  class='flex_column av-2y29t5-8eac002ebd25dfff14a3d2eed1a49041 av_one_full  avia-builder-el-5  el_after_av_section  el_before_av_post_metadata  avia-builder-el-first  first flex_column_div  '     ><style type=\"text\/css\" data-created_by=\"avia_inline_auto\" id=\"style-css-av-m8gaohgy-e779b05cc50cec788c64ad3beca2e266\">\n#top .av_textblock_section.av-m8gaohgy-e779b05cc50cec788c64ad3beca2e266 .avia_textblock{\nfont-size:40px;\n}\n<\/style>\n<section  class='av_textblock_section av-m8gaohgy-e779b05cc50cec788c64ad3beca2e266 '   itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/BlogPosting\" itemprop=\"blogPost\" ><div class='avia_textblock'  itemprop=\"text\" ><p style=\"text-align: center;\"><strong>So Many Risks and Faults at Stake<\/strong><\/p>\n<\/div><\/section><\/div><div  class='av-post-metadata-container av-av_post_metadata-f2d93833baf55c47e6bd6c86e40f308e av-metadata-container-align-center  avia-builder-el-7  el_after_av_one_full  el_before_av_hr  av-metadata-container-1'><div class='av-post-metadata-container-inner'><span class=\"av-post-metadata-content av-post-metadata-meta-content\"><span class=\"av-post-metadata-content av-post-metadata-published\"><span class=\"av-post-metadata-published-date\" >16. September 2020<\/span><\/span><span class=\"av-post-metadata-content av-post-metadata-separator\">|<\/span><span class=\"av-post-metadata-content av-post-metadata-category\"><span class=\"av-metadata-before av-metadata-before-categories\">in<\/span><span class=\"av-post-metadata-category-link\" ><a href=\"https:\/\/www.cohu.com\/category\/thought-leadership\/\" >Thought Leadership<\/a><\/span><\/span><\/span><\/div><\/div><\/p>\n\n<style type=\"text\/css\" data-created_by=\"avia_inline_auto\" id=\"style-css-av-m8t25391-39260fa6e7d6022a5f36742c2f35864e\">\n#top .hr.hr-invisible.av-m8t25391-39260fa6e7d6022a5f36742c2f35864e{\nheight:50px;\n}\n<\/style>\n<div  class='hr av-m8t25391-39260fa6e7d6022a5f36742c2f35864e hr-invisible  avia-builder-el-8  el_after_av_post_metadata  el_before_av_one_full '><span class='hr-inner '><span class=\"hr-inner-style\"><\/span><\/span><\/div>\n<div  class='flex_column av-1ltc3hq-d678e11ab7342dc0fff705952edff81f av_one_full  avia-builder-el-9  el_after_av_hr  el_before_av_hr  first flex_column_div  '     ><style type=\"text\/css\" data-created_by=\"avia_inline_auto\" id=\"style-css-av-14x5t1q-1d3d1b3ac94d5a75f3972da84176c0fc\">\n.avia-image-container.av-14x5t1q-1d3d1b3ac94d5a75f3972da84176c0fc img.avia_image{\nbox-shadow:none;\n}\n.avia-image-container.av-14x5t1q-1d3d1b3ac94d5a75f3972da84176c0fc .av-image-caption-overlay-center{\ncolor:#ffffff;\n}\n<\/style>\n<div  class='avia-image-container av-14x5t1q-1d3d1b3ac94d5a75f3972da84176c0fc av-styling- avia-align-center  avia-builder-el-10  avia-builder-el-no-sibling '   itemprop=\"image\" itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/ImageObject\" ><div class=\"avia-image-container-inner\"><div class=\"avia-image-overlay-wrap\"><img decoding=\"async\" fetchpriority=\"high\" class='wp-image-45864 avia-img-lazy-loading-not-45864 avia_image ' src=\"\/wp-content\/uploads\/2025\/03\/So-Many-Faults-At-Stake-Banner-Size-1030x361.png\" alt='' title='So-Many-Faults-At-Stake-Banner-Size'  height=\"361\" width=\"1030\"  itemprop=\"thumbnailUrl\" srcset=\"\/wp-content\/uploads\/2025\/03\/So-Many-Faults-At-Stake-Banner-Size-1030x361.png 1030w, \/wp-content\/uploads\/2025\/03\/So-Many-Faults-At-Stake-Banner-Size-300x105.png 300w, \/wp-content\/uploads\/2025\/03\/So-Many-Faults-At-Stake-Banner-Size-768x269.png 768w, \/wp-content\/uploads\/2025\/03\/So-Many-Faults-At-Stake-Banner-Size-705x247.png 705w, \/wp-content\/uploads\/2025\/03\/So-Many-Faults-At-Stake-Banner-Size.png 1200w\" sizes=\"(max-width: 1030px) 100vw, 1030px\" \/><\/div><\/div><\/div><\/div>\n<style type=\"text\/css\" data-created_by=\"avia_inline_auto\" id=\"style-css-av-m8g8t5wg-76ecfb6e051b02404cc71f111581bb48\">\n#top .hr.hr-invisible.av-m8g8t5wg-76ecfb6e051b02404cc71f111581bb48{\nheight:50px;\n}\n<\/style>\n<div  class='hr av-m8g8t5wg-76ecfb6e051b02404cc71f111581bb48 hr-invisible  avia-builder-el-11  el_after_av_one_full  el_before_av_one_full '><span class='hr-inner '><span class=\"hr-inner-style\"><\/span><\/span><\/div><\/p>\n<div  class='flex_column av-tc5sy6-c610ce4ce37ddc8755f7c103673cd0c6 av_one_full  avia-builder-el-12  el_after_av_hr  avia-builder-el-last  first flex_column_div  '     ><style type=\"text\/css\" data-created_by=\"avia_inline_auto\" id=\"style-css-av-m8g8tpp9-ff1fa86bc0dd446fd91b41108625f035\">\n#top .av_textblock_section.av-m8g8tpp9-ff1fa86bc0dd446fd91b41108625f035 .avia_textblock{\nfont-size:18px;\n}\n<\/style>\n<section  class='av_textblock_section av-m8g8tpp9-ff1fa86bc0dd446fd91b41108625f035 '   itemscope=\"itemscope\" itemtype=\"https:\/\/schema.org\/BlogPosting\" itemprop=\"blogPost\" ><div class='avia_textblock'  itemprop=\"text\" ><p>Some take the reliability of critical equipment and systems for granted, but those tasked with keeping them operational are keenly aware of the threats. Because there are so many potential risks and faults to manage, advanced condition monitoring and analytics are needed to hold them at bay. The Tignis solution can detect a minimum of eight different types of errors or unfavorable conditions, enabling a comprehensive path to reliability and optimization for connected industrial systems.<\/p>\n<p>While most plants do not have the necessary data to immediately start utilizing supervised ML, many plants have collected at least a few months of historical sensor data. With this data, here are examples of classes of faults that Tignis can detect using anomaly detection and engineering principles:<\/p>\n<ul>\n<li><strong>Mis-sized or out-of-spec equipment:<\/strong>\u00a0Tignis can detect incorrect or improperly sized equipment. For instance, a pump that had been shipped from the manufacturer with the wrong size impeller inside could have produced devastating outcomes had it not been discovered by the software. Another example is valves not sized for the expected differential pressure, which can make them hard to control.<\/li>\n<li><strong>Out-of-control \/ unstable controls:\u00a0<\/strong>Almost every plant that Tignis monitors has an automated control loop that attempts to maintain certain setpoints. Control loops must be tuned to ensure that they are stable and will always converge. Just as a car constantly overcorrecting will swerve back and forth, posing a dire hazard, issues like this can occur in control systems. They are technically \u201cout of control\u201d not only because they may never reach the setpoint in some cases, but the oscillations can propagate through the system and cause havoc in unpredictable ways. Tignis has detected and resolved issues where systems had multiple control loops that interacted with each other in unpredictable ways.<\/li>\n<li><strong>Sensor failures:\u00a0<\/strong>Stuck sensors, bias sensors, drifting sensors, mis-calibrated sensors\u2014Tignis has discovered these and more. Failed or failing sensors can invalidate decisions made based on their readings. In systems with automated control loops, a bad sensor means an incorrect control decision. Depending on how bad the sensor error is, outcomes could be catastrophic.<\/li>\n<li><strong>Mechanical wear and obstruction:<\/strong>\u00a0When the right sensors are available, Tignis can pay close attention to the amount of work a system is doing and compare it to the power utilization of the associated assets. When changes or trends in asset or system efficiency are identified, it often can be traced back to problems such as a bearing that is starting to wear, a filter that is becoming clogged, fouling on the inside of pipes, or stuck and leaky valves or dampers. Identifying these issues when they are just emerging provides time to avoid critical conditions and failure.<\/li>\n<li><strong>Hidden component failures:<\/strong>\u00a0Tignis brings hidden conditions to light. For example, large and complex monitored systems often have redundant components. In the case of multiple fans ventilating a cleanroom, when one fan fails, another can provide the full service, but that \u201cbackup\u201d fan is now the \u201ccritical\u201d system as it does not have its own backup. If Operations is unaware of the primary fan\u2019s failure and need for repair or replacement, it puts the cleanroom at risk. Another hazard is intermittent or momentary component failures, which can precede a complete failure. These, too, may be missed by Operations if not automatically detected.<\/li>\n<li><strong>Automation programming errors:\u00a0<\/strong>PLCs and similar control hardware must be programmed. The quality of automation programming can be highly variable, particularly with respect to handling exceptional conditions. When a system enters a state that was not predicted by the programmer, unexpected results may occur and lead to unanticipated and potentially catastrophic situations. Tignis\u2019 automation can detect some or many of these errors by monitoring the resulting physical properties.<\/li>\n<li><strong>Incorrect schematic data or incorrectly labeled sensors:\u00a0<\/strong>P&amp;IDs are not always updated correctly, and sensor tags are frequently wrong or undecipherable. These issues raise the potential for detrimental events, as both humans and computers may be making decisions based on faulty knowledge of how the system is built or currently being operated.\u00a0Tignis can help to detect such errors so they can be proactively corrected.<\/li>\n<li><strong>Violations of best practices or regulatory compliance:<\/strong>\u00a0Most plants have well-documented design standards for equipment, and some plants are subject to governmental regulations. The standards and requirements can be encoded in Tignis\u2019 proprietary query language and continuously monitored to prevent violations.<\/li>\n<\/ul>\n<p>Staying on top of all the possible threats is easier with an intelligent, physics-driven condition monitoring and analytics solution. There is no better way to keep your critical assets running reliably and help your company consistently meet its performance objectives.<\/p>\n<\/div><\/section><\/div>\n","protected":false},"excerpt":{"rendered":"","protected":false},"author":35,"featured_media":45864,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":"","_links_to":"","_links_to_target":""},"categories":[413],"tags":[],"class_list":["post-45863","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-thought-leadership"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v26.7 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>So Many Risks and Faults at Stake - Tignis | Cohu<\/title>\n<meta name=\"description\" content=\"Classes of faults that Tignis can detect using anomaly detection and engineering principles.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.cohu.com\/tignis\/so-many-risks-and-faults-at-stake\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"So Many Risks and Faults at Stake - 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