Controller upgrades
Upgrade ageing generator controls without losing the operating intent.
We help migrate unsupported generator controllers, PLCs, HMIs and SCADA systems into supportable platforms with clear documentation, testing and handover records.
Legacy PLCsGenerator controllersHMI upgradesSCADA migrationsDocumentation recovery
Migration planning
Controls upgrades need careful discovery before replacement
Many older systems keep running because people know their quirks. Before replacing hardware, the control intent, field wiring, controller settings, alarms and operator expectations need to be captured.
- Control-system audits and existing-state documentation
- PLC, HMI, controller and SCADA upgrade planning
- IO mapping, wire checking, signal testing and functional descriptions
- Cutover support, commissioning records, backups and operator handover
Upgrade triggers
When to review a generator controls upgrade
Unsupported hardware
Controllers, PLCs or HMIs are difficult to replace, back up or connect to modern support tools.
Poor visibility
Operators cannot see enough about alarms, running state, load, trips or historical events.
Documentation gaps
Drawings, software backups, setpoints or IO records are missing, outdated or unreliable.