When plant trips occur due to control system failures, the consequences can be far-reaching, affecting both production quotas and confidence in plant operations. Despite the best efforts to identify and correct the root causes, many trips go unresolved. The pressure to maintain production, limited testing resources, transient errors, and a lack of expertise often prevent engineers from performing thorough analyses. To mitigate these issues, a systematic approach using root cause analysis techniques, such as error traps, collaboration with OEMs, and engaging experienced external teams, is essential for enhancing system reliability and preventing future trips.

Poorly written or misinterpreted control narratives can introduce hidden flaws into control systems—flaws that only reveal themselves under certain plant conditions. In this post, we explore the real-world consequences of poor control strategy design and how rigorous testing, simulation, and collaboration between engineers and operators can uncover and prevent costly errors.

A single faulty field instrument can disrupt processes, compromise safety, and lead to costly downtime. This post explores the consequences of instrumentation failure, the common causes behind it, and practical steps to protect your plant.

Control system failures can lead to anything from minor process disruptions to major safety hazards. Understanding the common causes—like lack of redundancy, outdated technology, and design oversights—is key to preventing costly downtime. In this blog, we break down the risks and share expert solutions to improve system reliability and safety. Read more to ensure your plant stays protected.

Unmanaged changes to control systems can lead to costly mistakes, security risks, and compromised plant performance. Learn why documenting every update is crucial and how structured processes, automation, and access control can safeguard your operations.