Upgrades • Modifications • Integration
Upgrade PLCs, SCADA and functions without stopping the plant you depend on.
Sound familiar?
Most plants run on control systems older than the people who now maintain them. Spares get harder to find, the code is hard to follow, and every new machine or process change has to be squeezed into a system never designed for it. Replacing everything at once is rarely affordable, and production cannot stop for long.
How it works
We start by finding out what you really have: hardware, versions, code and documents. Then we plan the upgrade around your production: what to replace, what to keep, and in which outage. Existing logic is analysed and carried across, not guessed at; new functions and equipment are engineered in, and every change is tested before it reaches site.
What we do
From a single new function to a complete control system replacement, on existing plant or new, across every discipline that meets the control system.
Obsolete PLCs and controllers replaced by current ones: for example Siemens S7-300 and S7-400 to S7-1500, STEP 7 Classic to TIA Portal, or older Rockwell controllers to ControlLogix. Code is converted and reviewed, not just copied.
Industries: Airports, Baggage Handling, Clean Water, Heat Treatment, Metals, Mining and Quarrying, Nuclear, Oil and Gas, Power, Rail, Wastewater
Engineering projects, firmware and SCADA brought up to supported versions, such as older TIA Portal projects to the current release, with every version archived and under version control.
Industries: Nuclear, Pharmaceutical
End-of-life operator panels and SCADA replaced. Screens, alarms, trends and scripts are carried across and tested against the PLC before the old system is switched off.
Industries: Airports, Building Services, Clean Water, Power, Rail, Wastewater
New modes, sequences, recipes, reporting and data added to a system that already runs, without rewriting the parts that work.
Industries: Aerospace, Agriculture, Chemicals, Food and Beverage, Heat Treatment
New lines, machines and equipment added to an existing system, or a new system tied into the old. Each change is engineered, tested and made under change control.
Industries: Aerospace, Automotive, Baggage Handling, Chemicals, Oil and Gas, Pharmaceutical, Warehousing
Process, mechanical, instrumentation, drives, robots, vision and safety brought into one control system, with every interface agreed, documented and tested.
Industries: Agriculture, Automotive, Building Services, Food and Beverage, Metals, Mining and Quarrying, Warehousing
Many upgrades are best done in stages: SCADA first, then controllers line by line, then new functions. We plan the stages with you so that each one leaves the plant fully working and documented, and the next one is ready to start.
Industries
An ISO 9001 certified quality system, designing to the standards your sector demands, plus any you specify.
Our promise
How we deliver
Every upgrade follows the same path, whether it is one new function or a whole plant.
Hardware, versions, code and documents recorded; a backup of what runs today taken and proven restorable.
Existing code analysed, and the I/O list, alarm list and functional description recovered from it.
Upgrade path, stages, outage windows, cut-over and rollback agreed with you.
Code converted or written, new equipment and functions engineered in, to your standards.
Tested against a simulated plant and the old system's behaviour, then factory acceptance.
Installed in your outage, commissioned and site tested, then supported for the long term.
In full
Most projects do both: an existing system is modernised while new equipment is added to it. Each side needs a different kind of care.
Production depends on it. We change it without losing what it does today.
New machines and packages arrive from many suppliers. We make them work as one plant.
| Discipline | What we integrate | How it is proven |
|---|---|---|
| Process | Control philosophy, loops, sequences and recipes, agreed with your process engineers | Sequence tests and process trials |
| Mechanical | Pumps, valves, conveyors, guards and pressure systems: signals, limits and failure positions | Interface and failure-position tests |
| Instrumentation | Transmitters, analysers, flow, weighing and level: ranges, scaling, alarms and trips | Loop checks and calibration records |
| Drives and motion | Variable speed drives, servos and motion over fieldbus, with parameters archived | Drive tests and parameter record |
| Vision and robots | Camera inspection and robot cells: triggers, results, rejects and recipes exchanged with the PLC | Handshake and reject tests |
| Safety | Emergency stops, guarding, safety PLCs and relays, to your safety requirements | Safety requirements tests, independently reviewed |
| Networks and data | PROFINET, EtherNet/IP, Modbus and OPC UA; links to historians, MES and ERP; segmented networks | Communications tests and network records |
Older TIA Portal archives opened, upgraded to the current release and exported for review.
STEP 7 Classic statement list converted for S7-1500, with every rewrite marked for review.
Maps blocks, sequences, I/O and alarms, and flags faults before anything changes.
I/O, alarm and cause-and-effect lists produced from the code itself.
The upgraded program run in PLCSIM Advanced with simulated inputs before site.
Every version and change kept, so you can see exactly what changed and why.
FAQ
No. We can upgrade in stages, keep what works, and plan each stage around your production.
No. We recover the I/O list, alarm list and a functional description from the code before we change it.
Every cut-over has a rollback plan and a proven backup, so the old system can be restored.
Contact
Standards-led, fully documented control systems that you own and can support.
