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In What Ways Have You Seen PLC Failure?

10/11/2013 11:15 AM

PLC (Programmable Logic Controller) Failures and PLC failure rates.

Thought this forum would be a great place to collect real examples of root causes (RCA) of PLC failure from all the experienced experts here. This is in conjunction with the article recently curated by Control Magazine titled "PLC Controller Failure Rate". <<< click to review for proper context before replying.

For example in the article it mentions there are exceptions to the PLC failure rules, and one engineer replied with example in his foundry, where metal dust causes more PLC backplane failures than normal. What are your experiences with PLC failures so we all can learn more, prepare and increase reliability.

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#1

Re: In what ways have you seen PLC failure?

10/11/2013 11:45 AM

This belongs in the Commercial Section.

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#2
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Re: In what ways have you seen PLC failure?

10/11/2013 12:00 PM

Agreed, given that the OP would likely take our input, then use it to create their training courses and get paid for it. BIN95 is not an engineering service, it's more like a private school. Schools typically do their own research or use properly credited documents already in existence. Some of the stuff I have seen on BIN95 videos is a bit too anecdotal for my taste, I'd rather not contribute to that kind of thing being done for profit. A better approach would be to solicit white papers from qualified engineers, who can then decide if they want to be compensated or not for your commercial use and publication of their work.

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#3

Re: In What Aays Have You Seen PLC Failure?

10/11/2013 9:53 PM

I've had several failures of PLC's in foundries:

Iron poured over a remote I/O rack
Swinging ladle smashing an I/O rack to pieces
Iron spilling in to the cable ducts and setting fire to two of the I/O racks

Never had one fail due to dust, but we bought the correct equipment.

Nearly forgot one I/O rack run over by a FLT.

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#4
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Re: In What Aays Have You Seen PLC Failure?

10/12/2013 3:44 PM

Those are not failures, they are cases of field abuse.

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#5
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Re: In What Aays Have You Seen PLC Failure?

10/13/2013 10:50 AM

You try keeping a foundry running.

The operators are the enemy!

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#6
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Re: In What Aays Have You Seen PLC Failure?

10/13/2013 2:49 PM

Tony, you're 100% correct!

However, if we want this thread to make any sense, you've got to talk about PLCs that fail, not operator failures that destroy PLCs. The latter is a problem that management has to to struggle with --- no PLC is going to solve it for them.

Either this forum gets back on the track, or let it dry up.

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#7

Re: In What Ways Have You Seen PLC Failure?

10/14/2013 3:36 AM

Nil in 34 years. What's the prize?

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