Uncovering Hidden Risks: Why Control System Audits are Essential for Operational Reliability

After a control system is designed, built, programmed, commissioned, and started up, it is not uncommon for it to be overlooked. This is probably not the case for the control systems that run your main processes, but it can certainly be true for auxiliary systems that have been working reliably and seldom require any maintenance. Before you know it, that system may be 10, 20, or more years old. Should that system fail, sourcing parts may become a challenge. Without spare parts available, the resulting downtime may be much longer (and more costly) than expected.

Performing a full system audit and assessment helps you identify potential risks that may keep your facility from running well in the future. A system audit is more than just a health check — it’s a proactive strategy to safeguard your operations. By auditing your existing control systems, you could uncover hidden vulnerabilities, inefficiencies, and/or outdated technologies that could lead to costly, unplanned downtime.

The benefits of executing an audit and then analyzing the audit results are clear. This important exercise may:

• Identify obsolete equipment and unsupported software. The audit will provide a clear inventory of aging hardware, legacy components, or key software which is no longer supported by vendors.
• Determine potential physical security or cybersecurity vulnerabilities within your system. As vendors develop new technologies and release replacements for your current equipment, they often stop releasing patches or updated firmware for older components. Not only does this create intrusion risks, but it also means like-for-like replacements may no longer be possible.
• Uncover weak points within your system. Additional preventative maintenance tasks or more routine check-ups may be needed for older equipment to help reduce potential downtime and ensure operational continuity.

A proper audit doesn’t just highlight challenges — it can also help prioritize them. Once the audit is complete, a risk assessment should be conducted.

For each control system, consider the following:

Availability of spare parts on-hand. Can critical parts be purchased from an approved distributor or on the secondary market?

Supportability of the system. Can you find someone who knows how to troubleshoot a system installed in the 1990’s?

Condition of the control system. Are there accurate drawings? Backups? Is the cabinet wiring neat and clean, or are your technicians nervous every time they must work inside that panel?

Financial risks of downtime. How much downtime can you comfortably afford?

System dependency. If this system goes down, will other units be forced down?

Key account risks. Will you lose your best customer if you can't make their next shipment?

By recognizing your system’s most critical vulnerabilities, you gain clarity on which areas need immediate attention versus those that can be scheduled for a future upgrade. This insight empowers you to make data-driven decisions that optimize both risk reduction and resource allocation.

Applied Control Engineering, Inc. (ACE) has the experience and expertise to help you understand and categorize the control system risks that may be present in your facility. To assess system risks and advise where capital should be allocated for control systems upgrades, it is key to work with both customers and technology vendors. Our team will collaborate with your engineering and operations groups to ensure you understand which systems are the most vulnerable and where to focus your efforts to best reduce your risk of lengthy, preventable downtime due to control system failures.

To learn more, visit our Support Services page or Contact Us to speak with an ACE expert.