Why PLC & DCS Systems Fail Without Condition Monitoring
The Risks of Ignoring Monitoring
Small equipment faults often go unnoticed without monitoring. Over time, they damage sensors, motors, and drives. Unexpected failures cause 8–12 hours of downtime. Ignoring monitoring increases repair costs by 25%.
Why Systems Lose Reliability
Real-time data is critical for reliability. Systems without monitoring fail 2–3 times more often. Equipment often runs until failure, shortening lifespan by 15–30%. Emergency repair costs rise about 20%.
Impact of Downtime on Operations
Unplanned downtime reduces productivity by 12–18% and can cost $100,000 per day in mid-size plants. Monitoring predicts downtime and cuts interruptions by up to 40%.
Data Snapshot
| Metric | Without Monitoring | With Monitoring |
|---|---|---|
| Annual Failures | 2–3× higher | Baseline |
| Downtime | 8–12 hours | 4–6 hours |
| Repair Costs | +25% | Baseline |
| Productivity Loss | 12–18% | 5–8% |
How Monitoring Helps
Condition monitoring detects vibration, temperature, and electrical issues early. Preventive actions reduce failures by 35–50% and extend equipment lifespan by up to 20%.
Steps to Improve Reliability
Identify critical assets.
Integrate sensors with PLC/DCS.
Analyze real-time data.
Adjust maintenance based on insights. Downtime can drop 30–45%, maintenance costs cut 25%.
Conclusion
Without monitoring, failures, downtime, and costs rise. Investing in monitoring ensures early detection, predictive maintenance, and higher productivity. Condition monitoring is essential for modern industrial automation.
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