Legacy System Modernization

PLC migration (PLC-5 / S7-300 → modern platforms), SCADA integration (Ignition / WinCC OA), pneumatic-to-DDC HVAC retrofit, arc-flash mitigation, NIST 800-82 / IEC 62443 cybersecurity hardening, digital twin pre-development, operator training.

Legacy System Modernization

We modernize aging infrastructure without total replacement through PLC upgrades, SCADA integration, and legacy HVAC retrofitting to bring 1970s-era facilities into 2026 compliance.

Pre-Defined Scope of Work

Legacy PLC upgrade (S5/PLC-5 to S7-1500/ControlLogix/M580)
SCADA/HMI migration (Ignition, WinCC, FactoryTalk View SE)
Legacy HVAC retrofit (pneumatic-to-DDC, BACnet integration)
Communication gateway installation (Modbus, BACnet, OPC-UA bridging)
2026 compliance alignment (energy, environmental, electrical codes)
Phased zone-by-zone cutover with zero total-plant shutdown
Updated loop diagrams, cause-effect matrices & operator training

Deliverables

Legacy asset inventory & obsolescence risk register
Converted PLC code with full annotation & simulation test report
As-built SCADA screen library & user manual
Commissioning checklist signed by operations & maintenance
Training attendance certificates & competency sign-off matrix