Legacy Control System Failures: How Bently Nevada Prevents Costly Industrial Automation Breakdowns

Degradation of outdated hardware components
Limited interoperability due to obsolete communication protocols
Accelerated wear from inadequate maintenance
Environmental stress (temperature fluctuations)
Cybersecurity vulnerabilities

Predictive analytics with real-time monitoring
Advanced sensors for anomaly detection (vibration, temperature, pressure)
System 1® software for data aggregation and insights
Early alerts to prevent issue escalation
Reduces unplanned downtime by up to 50%

Retrofitting for modern compatibility
Modular DCS designs for phased upgrades
Edge computing to bridge data silos
OPC UA protocols for third-party integration
Extended lifespan with reduced capital costs

Challenge: Frequent PLC failures at a U.S. power plant
Solution: APM tools and vibration analysis
Result: 43% downtime reduction
Annual savings: $2.1 million

Cloud-based remote diagnostics
Machine learning for failure pattern prediction
Alignment with Industry 4.0 standards
Ensures long-term operational resilience

Urgent action required for legacy system risks

Bently Nevada’s innovation-driven strategies

Enhanced productivity with cost reduction

Data-driven reliability for industrial automation