A customer of ours contacted us, explaining their entire wastewater facility was inoperable for almost 15 hours. They had assumed that a recent network change made by the IT department was the cause of the outage.

Once a technician arrived at the site, it was quickly identified that the PLC battery was dead. In conjunction with a power cycle by one of the plant technicians, this resulted in the program being erased from its memory.

It’s a story all too common in industrial controls and automation. We have all gotten that call—the dreaded erasure of a program or lost parameters. In those moments, we wish someone, anyone, had taken the responsibility to document, mitigate risk or even do a simple program backup. In this case, a dead battery that costs next to nothing shut down the plant for two whole shifts. Read More

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