Many plants keep producing with a control system installed twenty or thirty years ago. The system runs, but the hardware is no longer made, spare parts are dwindling and fewer people know the application. As ASP Otomasyon, we offer the opportunity to renew your existing automation system with minimal downtime and low cost.

When
Hardware, software or spare-part support has ended
Approach
Phased: parallel build, a short planned outage
Options
New generation, phased move, controller swap keeping the I/O
Safety net
A rehearsed rollback plan

Is it time to upgrade?

If your existing DCS automation system

  • has solid hardware and an operating system, but the hardware modules are no longer manufactured,
  • no longer gets support from the manufacturer (PC, network, CPU, I/O and so on) in case of failure,
  • cannot be guaranteed spare parts (stocks have run out),
  • can only be repaired and kept running by luck,
  • has lost software support (such as Windows XP or Windows 2003 Server),
  • depends on a shrinking number of people who know the running application,

it is time to renew it. Contact us without delay to hear solution proposals that will minimize your losses.

Why an upgrade is not rip-and-replace

Changing the control system of a running plant must be done without stopping production and with the risk kept manageable. That is why the work is split into phases: the new system is prepared next to the old one while it runs, proven in the factory, put into service in a short planned outage, and the way back is planned from the start.

Modernization phasesFive phases from inventory and risk assessment through target architecture, parallel build and FAT, a planned cut-over and stabilization.Inventory andriskHardware, I/O,applications,upper systems1TargetarchitectureSelection,migrationstrategy, schedule2Parallel buildand FATWhile the oldsystem runs3Plannedcut-overShort shutdown,site verification4StabilizationTraining,decommissioningthe old system5Rollback plan ready and rehearsed
The rollback plan is part of every step from the third phase onward.
  1. Inventory and riskHardware, I/O, application software, upper-system interfaces and backups are listed; the most critical risks are ranked.
  2. Target architectureThe next generation of the same vendor, a different platform or a phased solution is assessed; the migration strategy and schedule are written down.
  3. Parallel build and FATThe new system is prepared while the old one runs and passes an acceptance test with simulation.
  4. Planned cut-overThe switch is made in a short outage with steps rehearsed beforehand; site verification follows.
  5. Stable operationTraining, documentation and backup routines are completed; the old system is retired after an observation period.

From Advant to System 800xA

For older-generation Advant Master systems, we stay with you through HMI upgrades, 800xA version upgrades, S100/S400 to S800 I/O upgrades and AC400 to AC800M CPU upgrades, with a phased roadmap that does not interrupt production. See the Advant DCS and System 800xA pages for details, and our migration roadmap article for planning.

Topics considered together with an upgrade

  • Virtualization: virtualizing servers for redundancy and easier maintenance.
  • Moving from OPC DA to OPC UA: removing the DCOM dependency.
  • Alarm improvement: reducing the operator workload.
  • Network and security: segmentation and secure remote access.
Legacy DCS modernizationHow to migrate without stopping production.Spare parts and lifecycleRisk-based planning.Virtualizing DCS serversWhen, how and with what risks?From OPC DA to OPC UAA DCOM-free, phased migration.

Frequently asked questions

Is it necessary to stop the plant to upgrade?

Usually a short planned outage is needed, but because most of the preparation is done while the old system runs, the outage is shorter. Unit-by-unit cut-over and wiring-preserving solutions can reduce it further.

Can the existing control logic be migrated as it is?

For some platforms automatic conversion with tools is possible; in most cases the result needs review and testing. Simplifying the logic can also be considered an opportunity.

Which systems should be renewed first?

Priority is set by weighing spare-part risk, dependence on a single person, security risk and process criticality together. A short consulting engagement can be enough for that.