Critical HMI Restored at a Gas-Fired Power Plant With Zero Interruption

About the Project

A gas-fired power plant experienced a sudden HMI failure inside a remote Plant Electrical and Equipment Control Center (PEECC). The malfunction placed essential control functions at immediate risk, creating the potential for major safety issues and disruption to ongoing operations.

Because the plant was enrolled in an Operational Technology Insights & Managed Services (OTIMS) program, the vulnerability had been identified in advance. This proactive insight enabled a rapid, interruption-free restoration without vendor escalation, hardware upgrades, or unplanned downtime.

Services Delivered

• OT Insights & Managed Services (OTIMS)
• Legacy System Identification
• Configuration Capture & Backup
• Emergency Response Support

The Challenge

• The HMI operated on obsolete hardware with an unsupported operating system, making failure likely.
• The system had not been maintained under standard IT lifecycle practices, increasing exposure to breakdown.
• The HMI outage removed access to critical local controls, creating immediate risks to safety, compliance, and plant availability.

The Solution

• During OTIMS discovery activities, the aging HMI was designated a high-risk legacy asset.
• Comprehensive configuration documentation and a complete backup image were created and securely stored as part of routine lifecycle management.
• When the malfunction occurred, the OT support function restored the HMI using the preserved image.
• Recovery required no vendor involvement, no extended lead times, and no emergency equipment purchases.

The Outcome

Zero Downtime

The HMI was restored immediately, ensuring uninterrupted operations and preventing production loss.

Improved Compliance & Safety Posture

Critical control availability was reinstated, supporting safe operating conditions and regulatory requirements.

Significant Cost Savings

Restoration was completed without relying on vendor troubleshooting, emergency service fees, or hardware replacement.

Proactive Risk Mitigation

Early identification and backup preparation through OTIMS minimized the impact of predictable hardware failure.

Stronger Operational Resilience

Plant leadership now has confidence in rapid recoverability even across aging systems, reinforcing long-term reliability.

This solution was delivered in partnership with ProArch.