Upgrade and retrofit programs for legacy PLC, SCADA and control infrastructure. Designed in stages around production windows, so modernisation happens without a full plant shutdown.
Upgrade and retrofit programs for legacy PLC, SCADA and control infrastructure. Designed in stages around production windows, so modernisation happens without a full plant shutdown.
Staged legacy modernisation planned around your production windows and your priorities.
Legacy modernisation requires careful planning because most sites cannot stop production for long periods. The work starts with asset criticality analysis, obsolescence risk review and dependency mapping across PLCs, drives, HMI nodes and network infrastructure. From there, phased upgrade plans align with planned outages, inventory availability and operational constraints. Typical upgrades include Allen-Bradley PLC-5 to ControlLogix, Siemens S7-300 to S7-1500, and end-of-life SCADA servers to current supported platforms. Temporary gateways or parallel running strategies are used where they reduce cutover risk. Detailed run sheets define pre-checks, decision gates, rollback triggers and communication responsibilities. For 24/7 manufacturing lines, this is the alternative to waiting for a complete plant shutdown event.
Retrofit projects blend engineering, site coordination and practical support after go-live. We deliver migration design, code conversion, simulation, FAT, SAT and onsite commissioning assistance, then remain available for optimisation once operators are using the new system. Documentation is updated in parallel: electrical drawings, software backups, alarm lists, network maps and operator guides. Training sessions for electricians, supervisors and maintenance planners ensure the new platform is understood across shifts. A common scenario is replacing an obsolete SCADA layer while retaining field devices and MCC infrastructure to fit a phased upgrade. This work is sequenced to preserve production visibility and avoid data gaps. Ongoing support contracts, planned maintenance visits and remote troubleshooting are available to keep upgraded systems stable across the years that follow.
We prioritise based on safety exposure, production impact, supportability and spare part risk. This puts the most urgent operational risks at the top of the schedule, while staying coherent with the longer-term modernisation roadmap.
Often yes. Staged cutovers, temporary interfaces and pre-tested migration packages keep downtime to a minimum. The exact strategy depends on process constraints and the shutdown windows available at your site.
Yes. Post-commissioning support, tuning, documentation updates and optional support contracts are available so your team has reliable assistance as the upgraded system beds in.
Speak directly with an engineer about scope, timing and technical constraints.
