Common Mistakes in Integrating Bently Nevada with PLC/DCS

Mistake 1: Ignoring Communication Protocols

28% of plants skip protocol checks. This leads to unstable data flow. Always confirm Modbus, OPC, or Ethernet support. Compatibility checks cut failures by 40%.

Mistake 2: Overlooking Power and Grounding

Improper grounding causes 20–30% of signal errors. Following manufacturer guidelines improves stability by 25% and extends system life.

Mistake 3: Incorrect Data Mapping

15% of alarm issues come from misaligned tags. Proper mapping reduces troubleshooting time by 30% and ensures accurate monitoring.

Mistake 4: No Redundancy in Critical Systems

One failure can stop production, costing $50,000 per hour. Adding redundancy raises system availability to 99.95%.

Mistake 5: Incomplete Testing Before Launch

42% of projects skip full testing. Simulation before commissioning lowers downtime risk by 35%.

Additional Risk Factors

Best Practices

• Involve automation and reliability teams early.
• Use a checklist for protocols, grounding, and redundancy.
• Run simulation tests at 100% load.
• Maintain vendor documentation and update logs.
• Train staff to cut errors by 20%.

Conclusion

By addressing these mistakes, plants can improve reliability, reduce downtime, and secure safer operations. Integration of Bently Nevada with PLC/DCS is a key step toward higher efficiency and global competitiveness.