How R.E. Mason Helped a Co-Gen Facility Regain Control

Repeated unit trips were disrupting operations at a high‑performing co‑generation facility, with each unexpected shutdown driving significant production losses. The issue stemmed from intermittent communication failures between control systems, triggered by configuration changes that caused the system to enter fault mode.

By addressing the communication breakdown between the PLC and I/O interface, the reliability team eliminated the trips and stabilized operations. In doing so, the facility removed the risk of millions in recurring losses and restored confidence in day‑to‑day performance.