Hot Cutover Consulting — Zero or Near-Zero Process Interruption
A hot cutover (live migration) lets you move from legacy control systems to modern DCS platforms without shutting down the plant. Our consulting delivers detailed procedures, parallel-operation plans, bump-less transfer strategies, and rollback contingencies.
Proven Hot Cutover Strategies We Recommend
Parallel / Shadow Mode
New controller runs in parallel with the old one (same inputs, outputs monitored but not connected to field). Ideal for PLC-5, SLC 500, and TDC3000 migrations.
Bump-Less Transfer
Gradual ramp of new controller outputs while old outputs remain active. Smooth handover with no process bump.
Sectional / Loop-by-Loop Cutover
Migrate one control loop or process unit at a time. Lowest risk for large, complex DCS systems like TDC3000, Foxboro I/A, or Bailey INFI90.
Redundant Processor Swap
Install new controller as a redundant pair, then switch over in minutes. Best for systems with built-in redundancy.
Our Hot Cutover Consulting Deliverables
- Detailed hot cutover roadmap and procedures
- Parallel operation monitoring plan and comparison tools
- Bump-less transfer logic and output tracking methods
- Sectional cutover sequences with rollback plans
- Operator and maintenance training materials for the transition