Why Industrial Control Systems Fail — And How Bently Nevada Helps Fix It
Why Industrial Control Systems Fail — And How Bently Nevada Helps Fix It
Discover the root causes of ICS failures and learn how Bently Nevada improves reliability with predictive monitoring.
Understanding ICS Failure Risks
Industrial systems run 24/7 in harsh environments.
65% of ICS failures result from aging hardware and environmental stress.
Heat and vibration reduce component lifespan by up to 50%.
Continuous monitoring helps detect early signs of wear.
Top ICS Failure Causes
- Power surges cause 30% of unplanned shutdowns
- Improper grounding leads to signal noise and data corruption
- Loose wiring accounts for 25% of short-circuits
- Manual inspection often misses early-stage issues
Why Reactive Maintenance Fails
Scheduled checks don’t reveal hidden faults.
Manual inspections are 70% less accurate than sensor-based systems.
$260,000/hour can be lost due to downtime.
Preventive strategies often come too late.
Bently Nevada Predictive Monitoring in Action
- Real-time monitoring of 90+ parameters using vibration and temperature sensors
- 3500 Series platform enables high-frequency sampling
- Clients report up to 60% fewer outages
- Maintenance costs drop by 30% on average
Smart Integration with PLC & DCS
Bently Nevada integrates with:
- Siemens, ABB, Rockwell PLCs
- Supports Modbus, OPC UA, and Ethernet/IP protocols
- Improves response time by 35%
- Visual data dashboards enhance operator awareness
Maintenance Method Comparison
| Feature | Traditional | Bently Nevada |
|---|---|---|
| Approach | Reactive | Predictive |
| Downtime Risk | High | Low |
| ROI | Uncertain | 300%+ |
| Maintenance Frequency | Fixed Intervals | Condition-Based |
Proven Benefits & Long-Term Value
Clients see 40–70% fewer shutdowns in the first year.
Unplanned maintenance calls drop by 25%.
System lifespan increases, downtime costs decrease, and efficiency improves site-wide.
Final Thought: Shift from Reactive to Proactive
Predictive monitoring is no longer optional—it’s essential.
Bently Nevada provides proven tools for reliability-centered operations.
Investing now prevents failure, protects assets, and ensures uptime.
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