Our Obsolescence & Reliability Services
We provide independent, unbiased guidance that fits your process, your budget, and your timeline — never pushing a single vendor solution.
5-Year Obsolescence-to-New Roadmap
IEC 62402-aligned risk assessment and phased migration plan from legacy systems to modern DCS platforms. Includes spares strategy, hot-cutover options, and budget-conscious hybrid solutions.
Honeywell TDC3000 Reverse Engineering
Full reverse engineering of legacy TDC3000 systems (LCN, AM, APM, CL programs) with minimal documentation, plus a phased migration roadmap to Experion or other modern platforms.
Learn more →SLC 500 Reverse Engineering
Full reverse engineering of legacy SLC 500 ladder logic with minimal documentation. Includes functional specification, modern tag database, and phased migration roadmap.
Learn more →Allen-Bradley PLC-5 Reverse Engineering
Full reverse engineering of legacy PLC-5 ladder logic, with functional specification, modern tag database, and phased migration roadmap to ControlLogix or CompactLogix.
Learn more →Ladder Logic Modernization
Modern DCS with the familiar ladder logic look and feel your team already knows — a ladder-friendly function block library plus side-by-side documentation.
Learn more →Bailey INFI90 Reverse Engineering
Complete reverse engineering of legacy Bailey INFI90 DCS systems with minimal documentation, plus a phased migration roadmap to modern platforms.
Learn more →Foxboro I/A Series Reverse Engineering
Complete reverse engineering of legacy Foxboro I/A Series DCS systems with minimal documentation, plus a phased migration roadmap.
Learn more →Siemens Moore APACS / Quadlog
Complete reverse engineering of legacy Siemens Moore APACS and Quadlog systems with minimal documentation, plus a phased migration roadmap.
Learn more →Emerson Provox / RS3
Complete reverse engineering of legacy Emerson Provox and RS3 systems with minimal documentation, plus a phased migration roadmap.
Learn more →Hot Cutover Strategies
Zero-downtime migration roadmaps, parallel operation plans, bump-less transfer, and sectional cutover strategies for legacy DCS and PLC systems.
Learn more →Service Agreement Strategy & Negotiation
Structure and renegotiate service/lifecycle agreements in your favor — built by a more than 25-year insider who designed and sold these programs. Cut cost, expand coverage, and gain real leverage with major vendors.
Learn more →Hybrid Upgrade Solutions
Cost-effective combinations of legacy retention, form-fit-function replacements, partial I/O migrations, and new technology integration — tailored to your budget.
ISA-95 & OPC UA Integration
Connect legacy DCS/PLC systems with modern MES, ERP, and cloud platforms using standardized, secure models and roadmaps.
Learn more →Platform-Specific Expertise
Deep experience with Yokogawa Centum VP / ProSafe, Emerson DeltaV / Ovation, Honeywell Experion / TDC3000, Rockwell Allen-Bradley PLCs, and Aspen Tech systems. We are completely vendor-neutral — our recommendations are based solely on what is best for your process, your safety requirements, and your budget, often combining legacy systems with targeted modern upgrades to deliver maximum ROI.
Case Study: 5-Year Obsolescence Roadmap
Major Refinery – Honeywell TDC3000 to Modern Hybrid Platform. A large U.S. refinery was running a 22-year-old TDC3000 with critical spares shortages and increasing downtime risk. We delivered a vendor-neutral IEC 62402 5-year roadmap with risk matrix, spares optimization, hot-cutover strategy, and hybrid upgrade options.
- Extended reliable operation of the existing system by 4–5 years
- Identified $1.2M in avoided capital spend through the hybrid approach
- Phased migration plan with zero unplanned shutdowns
"ROI gave us a practical, budget-aligned roadmap instead of the usual vendor push for a full replacement. We saved millions and gained operational certainty."
— Reliability Manager, Major RefineryOur Simple, Secure & Low-Risk Process
Data Collection
You provide basic information such as spares inventory, support contracts, failure history, and EOL notices. No special tools or system access required.
Secure, Encrypted Upload
You upload files through our secure, encrypted portal. We sign a mutual NDA before any data is reviewed.
Risk Assessment & Roadmap
We perform a detailed IEC 62402-aligned analysis and deliver a clear 5-year roadmap with prioritized recommendations and implementation guidance.
What You Receive
- IEC 62402 risk matrix with prioritized recommendations
- 5-year phased roadmap including hot-cutover options and hybrid solutions
- Spares optimization strategy and lifecycle cost projections
- Clear, step-by-step instructions your internal team or System Integrator can follow
Result: 2–5 years of additional reliable operation, thousands to millions in avoided capital expenditure, and a practical path forward that fits your budget and timeline.
Where ROI saves you money on your DCS/PLC migration
A modern migration already keeps your existing field I/O and wiring — that is the right approach. So the savings are not mechanical, they are commercial: the vendor still scopes and prices the migration to maximize their sale. With more than 25 years on the vendor side, we make sure you do not overpay for the migration you are already going to do.
Right-size the scope
Trim padded engineering, over-specified software, and licenses you won’t use — while keeping the redundant controllers and I/O that protect uptime.
Negotiate the commercial deal
Insider knowledge of how vendors price migrations: list-to-net discounts, and license and support terms.
Cut the lifecycle / service agreement
A typical agreement runs about 2% of the installed base per year; we renegotiate it lower — recurring savings for years, not a one-time win.
Level competing vendor bids
Several vendors quoting the same job? We normalize every bid to one scope for a true comparison, expose the padding and change-order traps, and use the competition to cut your price.
Phase to your budget & turnarounds
Remove the vendor’s end-of-life deadline leverage; defer non-critical scope to later capital cycles.
Owner’s engineer through delivery
Review proposals, FAT / SAT, and control the change orders and overruns where migrations quietly bleed.
On an average 10,000 I/O migration: roughly 20–25% off the project cost, plus about $70–90K per year off the lifecycle agreement — and ROI’s fee is a fraction of what it saves you.
Illustrative · anchored to your actual vendor proposalWant the full breakdown? Download the DCS Migration Savings one-pager (PDF) →