CAP / 01
PLC control systems
Program architecture, standards-based function blocks, safety interlocks and a documented I/O list you can maintain after we leave.
SERVICE 02
Automation & controls
The program that runs the plant.
Scope of works
What's included
Legacy upgrade and plant migration, DCS and PLC programming, SCADA and HMI development and complete control system integration — built on industry-standard platforms with full traceability.
- Legacy upgradeAn obsolete controller taken to a current platform without a rewrite from scratch. Proven logic is converted and restructured into maintainable blocks, not replaced with a guess at what it did.
- Plant migrationA running plant moved onto new control hardware in phases, around your shutdown windows, with the legacy system and a verified program image kept on site until sign-off.
- DCS / PLC programmingProgram architecture in standards-based function blocks, with the interlock matrix and I/O schedule written down and handed over as commented source your own team can maintain.
- SCADA / HMI developmentOperator screens built around the task rather than the tag list — alarm rationalisation, trending and historian tie-in, so the screen answers the question an operator actually has.
- Control system integrationInstruments, drives and third-party skids brought under one control philosophy, so the plant behaves as one system rather than several that happen to share a building.
Siemens · Rockwell · Honeywell · Archestra
In detail
The disciplines that deliver it.
What actually gets engineered, built and signed off under this service.
CAP / 02
SCADA & HMI integration
Operator screens built around the task, not the tag list. Alarm rationalisation, trending, historian tie-in.
CAP / 05
System automation & controls
Sequence design, recipe and batch handling, VFD and servo integration, machine safety to the required category.
Legacy upgrade
Legacy PLC upgrade
When spares run out and the programming software only runs on one old laptop, we take the plant to a current platform without a rewrite from scratch and without an extended outage.
- 01
Siemens
S5 and S7-300/400 to S7-1500 on TIA Portal. Proven logic converted and restructured into maintainable function blocks, PROFIBUS moved to PROFINET, HMIs rebuilt in WinCC Unified.
- 02
Rockwell
PLC-5 and SLC 500 to ControlLogix or CompactLogix on Studio 5000. Conversion kits keep existing terminations in place so changeover fits a planned shutdown; HMIs rebuilt in FactoryTalk View.
- 03
Cross-platform migration
Moving between vendors in either direction. The control philosophy, interlock matrix and I/O list are documented platform-independent first, and the new program is written against that, so sequence behaviour stays identical and operators get a familiar plant.
- Full I/O documentation before hardware is touched
- Simulation at our works before anything reaches site
- Phased cutover around your shutdowns
- Parallel run on shadowed I/O where a hot cutover is needed
| Ref | What a legacy estate costs you | Consequence | Severity |
|---|---|---|---|
| R-01 | No spares, no support | Controllers installed decades ago are past end of life. Replacements come from grey-market brokers with no warranty and long lead times. | Critical |
| R-02 | Nobody can touch the logic | The original program often lives on one surviving laptop running obsolete software — undocumented, edited for years by engineers who have since left. | Critical |
| R-03 | Audits and data both fail | Flat, unauthenticated control networks fail cybersecurity review. Ageing controllers can’t feed the MES, historian and analytics you’re investing in. | High |
Rockwell Automation
Migration pathsLegacy processors→ControlLogix
Small-frame controllers→CompactLogix
Legacy programming software→Studio 5000
Standard operator panels→PanelView Plus
Legacy visualization→FactoryTalk View
Legacy networks→EtherNet/IP
Siemens
Migration pathsLegacy SIMATIC processors→S7-1500
Legacy programming software→TIA Portal
Legacy operator panels→Comfort Panels
Legacy visualization→WinCC Unified
Legacy fieldbus→PROFINET
Standalone safety relays→Safety controllers
Tell us about the plant.
Send us the scope and we’ll put an engineer on it, not a salesperson.