Support and spare parts risk
Control, drive and operator panel components approaching the end of their life cycle increase unplanned downtime and intervention uncertainty.
/ INDUSTRIAL SOLUTION
20
Automation System Upgrades and Retrofits
Modernise ageing controls in measurable steps while keeping production requirements in view.
We upgrade PLCs, HMI/SCADA, drives, control panels, networks and safety infrastructure in testable stages, with production risks and rollback plans defined in advance.
Explore the solution
Renew your outdated control infrastructure with a controlled program that makes the production risk visible, not at the time of failure.
Undocumented operating behaviour
If software, alarms, interlocks and field modifications are not reflected in current documentation, critical functions may be lost during migration.
Limited shutdown window
When upgrades must fit within short maintenance shutdowns, testing, cutover and rollback steps need to be demonstrated in advance.
Keep the current behavior;
move infrastructure into the future in a measurable way.
Modernisation involves more than replacing hardware. Document field behaviour, production recipes, interlocks, communications and safety functions, then validate the target architecture against that evidence.
Identify assets and risks
Hardware, software, network, backup, license and documentation status are recorded together.
→Confirm behavior
Record and verify cycles, recipes, alarms, interlocks, safety functions and operator actions in the existing system.
→Design the new architecture
Define migration boundaries for the controller, I/O, drives, HMI/SCADA, network and data layers.
→Manage cutover and rollback
Pre-test, backup, cutover, SAT, and rollback steps are carried out according to an approved plan.
/ SCOPE OF MODERNIZATIONIt's more than just a hardware change.
It's more than just a hardware change.
A controlled system life cycle.
Scope is prioritized based on business criticality and production risk; manageable transition packages are created instead of unnecessary bulk changes.
PLC and Distributed I/O
Transfer the program, addressing, field signals, interlocks and control behaviour to the new architecture with a traceable mapping.
HMI and SCADA upgrade
Screens are not just copied; they are reworked for alarm, trend, recipe, authorization, and availability needs.
Drive and servo systems
Motor, feedback, motion profile, torque and safety functions are validated with mechanical load.
Control panels, MCCs and field wiring
Review thermal loads, short-circuit withstand, protection, terminal blocks, cables and labelling, and update the documentation accordingly.
Industrial networking and integration
Network topology, segmentation, remote access and upper system communications are designed with continuity and security goals.
Safety, cybersecurity and data
Safety functions, access authorizations, backup and production data are validated as part of the new control architecture.
/ SAFE MIGRATIONManage a short shutdown window
Manage a short shutdown window
with a proven cutover plan.
- 01Backup and restore
Verified backups of the program, recipe, parameter, drive, and network configurations are prepared prior to migration.
- 02Simulation and FAT
Test the control logic, screens, alarms and communications in a test environment before the actual plant shutdown.
- 03Parallel verification
Where possible, old and new behavior is compared; critical signals and cycles are tracked with a checklist.
- 04Cutover and rollback
Assign responsibilities, timings, decision gates, SAT tests and rollback conditions in a minute-by-minute implementation plan.
From risk inventory to sustainable operations, Six controlled steps.
- 01Build the inventory
The status of hardware, software, network, control panel, documentation and spare parts is verified in the field.
- 02Document behavior
Document cycles, recipes, alarms, interlocks, safety functions and manual operating scenarios.
- 03Prioritize risk
Define the phases according to business criticality, failure likelihood, spare part availability and the impact of downtime.
- 04Design and pretest.
New architecture, software transformation, screens, and integrations are validated in the simulation/FAT environment.
- 05Complete cutover and SAT
An approved cutover plan is executed; field signals, safety, cycle and performance tests are completed.
- 06Complete the handover documentation
Hand over up-to-date drawings, software, backups, training, maintenance arrangements and the lifecycle plan to the operations team.
From a single machine to a facility layer.
Scalable modernization.
Machine control
Controlled upgrade of PLC, HMI, drive, I/O and safety functions in a single machine.
Production line
Phased modernization of synchronization between multiple machines, conveyors and stations.
Plant HMI/SCADA
Moving the distributed display, alarm, trend, recipe and reporting structure to a common operating standard.
Safety and data layer
Re-architecting at-risk legacy functions, network segmentation, and production data connections.
Let’s clarify your requirements
with the right engineering team.
Tell us briefly about your operation so we can establish the right next step together.
Discuss your requirements Your request is routed directly to the relevant engineering team.