Migration of Control Systems
Plenty of plants still run controllers and variable frequency drives (VFDs) that are 15 to 20 years old, no longer supported and with no spare parts available. We handle the full migration: surveying the existing logic, porting it to a current platform, replacing obsolete equipment, updating the operator interfaces and testing exhaustively so your process keeps running with no surprises.
When is it time to migrate?
No spare parts available
The manufacturer no longer makes the control card or the I/O module you need. One failure means weeks of downtime waiting for a used spare.
No technical support
Nobody can program, troubleshoot or modify your PLC or VFD because the software is two decades old and can no longer be licensed.
Growing operational risk
Electrolytic components (capacitors, fans) have a finite service life. After 12-15 years, the probability of failure grows exponentially.
A need for new functionality
Your process has evolved but the controller cannot take more I/O, modern communications or new protection logic.
How we execute a migration
Survey of the existing system
We document the PLC, I/O, HMI, VFDs and the existing control logic. If there are no drawings, we produce them.
Porting the control logic
We reproduce the original logic on the new platform. We do not reinvent your process — we migrate it faithfully and then optimize.
Selection of equivalent equipment
We map every obsolete component to its current equivalent. Danfoss VFDs, Siemens PLCs, compatible HMIs.
Panel retrofit
We build a new panel or adapt the existing one to take the new equipment. We keep mechanical changes to a minimum.
Phased migration
Where possible, we migrate section by section to reduce plant shutdown. Each phase is tested on its own.
Validation and documentation
SAT testing with the real process, parameter optimization, handover of as-built drawings, backups and training.
Migrations delivered
Do you have obsolete equipment with no support?
We assess your current system and hand you a migration plan with scope, cost and schedule.
Request a migration assessment