Masterflex Peristaltic Feed Pump

PM-204Head pressure above ceiling

Feed pump on Skid BR-UP-01 (2,000L Fed-Batch Bioreactor). Live readings from the historian, maintenance history from Maximo and spare stock from SAP — all read-only.

Asset class: peristaltic pump · GMP criticalSuite 3B (Grade B)Snapshot 08:26 UTC · T+264.4hDemo · read-only

Resolve schedule conflict View related yield analysis

Operating state

Last 1-min average · red tick = hard limit

Observation

Head pressure

1.48bar

Ceiling 1.20 bar

Tubing life expended

412/ 500 h

OEM life 400–500 h

Motor speed

184.2RPM

OEM tubing limit ≤ 200

1.48 bar vs 1.20 bar ceiling · delivered feed −14.2% at constant 184.2 RPM

Constant speed with falling delivery means less volume per revolution. That pattern fits tubing slip or over-occlusion, but is a hypothesis under INV-104, not a confirmed failure mode. INV-104

Tubing hours come from the CMMS run-hour counter reset at WO-8726; the tube has run across MES-26072 and MES-26073.

Asset record

Tag: PM-204
Model: Masterflex L/S
Pump head: Easy-Load II
Tubing: Size 24 Pt-silicone
Tubing lot: TS24-PT-5521
Clamp torque: 0.55 N·m
Pressure TX: PT-204 · cal. Oct 3
Governing SOP: SOP-UP-014 Rev 7

Correlated anomaly timeline

Head pressure (left axis) with MES-26073 delivered feed (right axis, dashed)

Head pressure (PM-204) (bar)— Feed rate MES-26073 (mL/min, right axis)

MES-26073Reference envelopeMissing telemetry (dashed = imputed, excluded from stats)

R² = 0.941 feed loss vs head pressure — correlation across 3 batches, not causal proof

Maximo work order ledger

PM-204 · last 30 days and scheduled

Date (UTC)	Type	Description	Status
Oct 26 06:00 (sched.)	CIP/SIP	BR-UP-01 feed skid CIP/SIP incl. PM-204 line, 06:00–14:00 Overlaps MES-26074 inoculation by 4.5 h · resolve	Scheduled
Oct 23 (planned)	Corrective	Tubing changeout + dynamic slip verification per SOP-UP-014 §7.2	Awaiting approval
Oct 17 07:12	Corrective	Occlusion clamp torque 0.42 → 0.55 N·m after audible chatter. Returned to service. Dynamic slip verification not performed (fixture unavailable)	Closed
Oct 3 13:20	Calibration	PT-204 discharge pressure transmitter · as-found +0.3% FS (tol. ±0.5%)	Closed · pass
Sep 26 20:05	Preventive	Scheduled tubing changeout · lot TS24-PT-5521 · gravimetric check −0.1%	Closed · pass

Spare parts availability

SAP stock · read-only extract

2 h old

Tubing · size 24 platinum silicone
96440-24 · Suite 3B airlock cabinet SB-3B-02
6
Gamma-irradiated · lot TS24-PT-5604 · exp. Apr 2027 · cleanroom-ready
Tubing · size 24 platinum silicone
96440-24 · Central warehouse WH-C-14
14
Needs transfer and wipe-down into Grade B
L/S Easy-Load II pump head
77200-62 · Maintenance crib MC-01
1
Not cleanroom-ready; transfer takes ~2 h
Pressure transmitter PT-204 spare
PT-204-SP · —
0
None in stock · lead time 10 days

Physical counts are not verified by ERP.

Proposed maintenance action

Drafted from INV-104 evidence · requires maintenance and QA sign-off

ProposalProposed · not approved · not executed

Rationale: Tubing is inside the OEM end-of-life window, the clamp was tightened without the SOP-required slip check, and delivery fell at constant RPM.
Expected result: Head pressure back below 1.20 bar and delivered feed within ±3% of setpoint at 184 RPM after changeout and verification.
Constraints: Can only run when BR-UP-01 is not in a GMP batch. Planned for the Fri 23 Oct CIP turnaround; the Mon 26 Oct 06:00–14:00 sanitization window already conflicts with MES-26074 inoculation; 6 cleanroom-ready tubes are available in the Suite 3B airlock.
Owner: K. Daniels (Maintenance) · Marcus Bell (Cleanroom Supervisor)
Required approval: Maintenance planner approval of WO-8848 in Maximo and QA concurrence under Q-DEV-031.
Would change this proposal: A slip test on the removed tube showing normal delivery (points away from tubing), or a PT-204 check showing the pressure reading is biased.

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