Ageing PLC technology is becoming a real issue for the reliable operation and safety of sailing yachts. Since 2000 the larger yacht industry has moved away from simple analogue alarm, monitoring and control systems with big synoptic panels to reduce weight, reduce space requirements and improve fault diagnostics and feedback. Along with motor and sail controls, systems controlled on larger yachts typically include hydraulics, electrical, alarm and monitoring.
As with all modern technology the pace of improvement over recent years means new products render older technology at a significant disadvantage. With older hardware entering end of support and manufacturing life cycle upgrades, spares not being manufactured and security and functionality firmware upgrades ceasing these critical systems become a source of concern and stress for crew, operators and owners. Obsolete PLCs can create many problems that affect operational efficiency, increase costs and create risks. With reliability issues creeping in, a simple component failure can end a yacht’s race or cruise. With a full race crew plus operating costs, losses can run into hundreds of thousands, not to mention the time lost for owners and guests.
There has been a continued move recently to more functionality and modern responsiveness which leaves older systems lagging behind in the smooth and safe operation of a successful vessel.
Upgrading to the latest technology brings with it many benefits: improved remote support, more user friendly and simpler user interfaces, wireless access using phones or tablets and improved insights and depth to the way a vessel is operating. Diverse Performance Systems offers a complete yacht control systems overhaul service where we replace all ageing or obsolete PLC hardware and software on the yacht. Our experience and in-depth knowledge of not only systems, but also of the complexities of modern yacht operations, means that systems upgrades are planned and executed with a keen focus on minimal disruption.
Updates are typically planned and executed alongside the yacht’s winter maintenance or refit period and completed to allow return to operations with as little disruption to the sailing programme as possible.
Key considerations when assessing existing systems are:
- Difficulty finding replacements: As PLCs age, spare parts become increasingly scarce and may be unavailable from the original manufacturer. This can lead to extended downtime if a component fails.
- Lack of technical support: Manufacturers may end support for older PLCs, meaning you won't receive firmware updates, software tool support, or technical assistance.
- Higher maintenance costs: Finding and replacing parts can be expensive, and the lack of support may require specialised knowledge.
- Compatibility issues: Inability to integrate with modern systems. Obsolete PLCs may not be compatible with modern communication protocols (like Ethernet or Modbus TCP) or other control infrastructure.
- Difficulty upgrading or expanding: Adding new functionality or integrating with newer technologies can be tricky due to compatibility limitations.
- Increased downtime risk: Unpredictable failures. Older PLCs may be more prone to failures, potentially leading to unplanned downtime and production delays.
- Lack of redundancy: Older systems may not offer the same levels of redundancy or fault-tolerance as newer PLCs.
- Cybersecurity vulnerabilities: Outdated software and protocols. Obsolete PLCs may run on older software or communication protocols that are more vulnerable to cyber attacks.
- Lack of security features: Older systems may lack the security features (like encryption or firewalls) found in modern PLCs. Skills gap: Finding technicians who are skilled in programming and maintaining older PLCs can be challenging.
- Difficulty training new personnel: Training new staff on older PLC systems can be more time-consuming and costly.
- Reduced efficiency and limited control capabilities: Older PLCs may not offer the advanced control features or capabilities found in modern systems.
- Higher energy consumption: Older PLC systems may not be as energy-efficient as newer models.
In summary, using obsolete PLCs can create a multitude of problems that can hinder operational efficiency, increase costs, and create significant risks for the owner, with reliability issues creeping in. Upgrading to a newer system can provide operational efficiencies, improved ease of use, improved security and peace of mind that the critical systems will perform when needed and to the level required. Operational downtime can be reduced and worry or stress over failures and the scarcity of parts is removed.
A modern, up-to-date system that is functioning correctly and backed by support and service from an experienced partner like Diverse Performance Systems provides for a safe, performing yacht that becomes easier to operate and enjoy.
