We upgrade existing control systems, coordinating engineering, programming and the on-site intervention. We prepare the migration and validate the functions so that the work fits the operating conditions of each facility.
Needs we address
Obsolescence
Replacement of controllers, I/O and supervision systems that are no longer manufactured or supported.
Technology upgrade of obsolete systems
Migration to current control platforms such as Siemens PCS 7, S7-1500 or Schneider Modicon M580, among others.
- Siemens S5
- Schneider Quantum and Premium
- Plants that require reverse engineering
Functional adaptation
Review of the logic and sequences to adapt them to how the plant operates today.
Maintainability
A documented, consistent system that is easier to diagnose, modify and maintain.
How we approach a migration
- 01
Survey of the existing installation
We analyse the current system: programs, signals, communications and equipment. When the documentation is not up to date, we apply reverse engineering to the program and the installation and redraw the drawings.
- 02
Planning and coordination
We plan the migration and coordinate the disciplines involved —engineering, programming, installation and operations— to fit the intervention to the plant’s shutdowns and conditions.
- 03
System adaptation
We adapt the programming, signals, communications and equipment according to the scope of each project.
- 04
Testing, commissioning and documentation
Function testing, on-site commissioning and delivery of the updated system documentation.
Reverse engineering and redrafting
Many installations to be migrated do not have up-to-date documentation. We carry out reverse engineering on the existing program and installation and redraw the schematics and drawings, so the migration starts from a real, documented state of the plant. It is the same team and the same tools as our basic and detailed engineering.
Basic and detailed engineering: electrical, instrumentation and control →
Validation with SIMIT before working on site
Where the project scope allows, we reproduce the behaviour of the process with Siemens SIMIT to check the logic, sequences, alarms and failure scenarios before the physical intervention.
Simulation with SIMIT allows checks to be brought forward and issues to be detected before the on-site intervention, helping to reduce the time needed during the shutdown and commissioning.
Experience in simulation and operator training: SIMIT simulation and OTS case → · Advanced simulation and Virtual Commissioning →
Featured case
01
Bunge: migration from Quantum/Premium to Siemens PCS 7
Complete turnkey project: replacement of the old Schneider Quantum and Premium PLCs with Siemens PCS 7, around 4,000 I/O signals, more than 50 drives and starters replaced, programming tests and operator training with SIMIT, and a one-month shutdown with 49 people on site.
Other migrations
01
Control migration of a crude oil pumping station
From SMAR controllers and Foundation Fieldbus to PCS 7 with redundant S7-400H controllers.
Related services: Industrial automation and DCS systems → · Basic and detailed engineering →
Ask us about modernising your system. Tell us which control system you have today and what you need to solve, and we will propose the scope of the migration.