Legacy DCS systems create significant risk. We help you address every major issue with fast, remote Quick Audits and roadmaps.
DCS/IT-OT convergence and cloud/IIoT connections expose legacy systems never designed for modern threats (e.g., Triton malware targeting SIS).
End-of-support spares shortages, discontinued firmware/OS, degrading components (capacitors, solder joints), and slow CPUs in plants >15 years old.
Operators overwhelmed by chattering, stale, duplicate, or irrelevant alarms — often thousands per day — leading to missed critical events.
Difficulty connecting legacy DCS to new MES, historians, AI analytics, power monitoring, or third-party systems without latency or data silos.
Intermittent faults, I/O loss, unexpected resets, and communication errors from aging components in harsh environments.
Single points of failure, packet loss, or delays in real-time control loops, especially with Fieldbus/Ethernet expansions.
Retiring experts on legacy systems + new hires lacking DCS-specific training; leads to misconfigurations or slow response during upsets.
Incomplete proof-testing, missing FSA (IEC 61511), poor SRS documentation, or inadequate DCS-SIS separation.
Massive data volumes without effective historians or AI-driven insights for energy management, PUE reduction, or predictive maintenance.
Difficulty expanding without rip-and-replace; dependency on vendors with poor support; escalating maintenance/spares costs.