Yesterday’s systems were a good investment, but today’s technology and expertise provide opportunities and benefits that just weren’t available when these systems were designed. Consider migrating when:

  • An impending threat of unscheduled downtime exists
  • Support for an old system is no longer cost-effective, the system is obsolete or being phased out or spare parts are no longer available
  • The old system cannot support new information technology that provides an economic advantage
  • A new business opportunity or process is impossible without a new system
  • The old system is inflexible and cannot react to rapid shifts in customer demand
  • The old system lacks the visibility into system operations that could prevent abnormal situations, equipment breakdown, disruptions in production, etc.
  • The old system does not have the needed capacity and expansion is not cost-effective

When you need to migrate a control platform, ECS can help you improve your plant operation to deliver more value and increase your return on investment.

ECS Migrations

ECS can migrate almost any control system to almost any other control system. The company has migrated customers from little-known control systems and developed tools to facilitate the following migrations:

  • DCS to PLC/PAC (for example, ABB Bailey to Allen-Bradley ControlLogix)
  • One brand of PLC/PAC to another brand of PLC/PAC (for example, Square D Symax to ControlLogix)
  • Modernization of a legacy platform (for example, Allen-Bradley PLC5 to ControlLogix)

ECS Migration Services

  • Strategic planning
    • Phased implementations
    • Network modernization
  • Implementation
    • Control system drawing updates or drawing development
    • Control system hardware
    • Servers/computers/workstations
    • Software translations/conversions/modernization
    • Panel fabrication
    • FAT
    • Installation
    • Commissioning and startup

ECS Technical Services (most major brands)

  • Controllers
  • Instrumentation
  • Variable frequency drives and motion
  • Operator interface terminals
  • HMI/SCADA systems
  • Data historians
  • Information technology

ECS Custom Software Applications

  • Software (.NET, Visual Basic, C#, HTML, etc.)
  • Databases (Access, SQL)

Average Cost of Downtime

(source: Meta Group: Quantifying Performance Loss)
Industry Average Hourly Downtime Costs
Energy (Including Oil & Gas) $2,817,846 USD
Discrete Manufacturing (Including Auto) $1,610,654 USD
Pharmaceuticals $1,082,252 USD
Food/Beverage Processing $804,192 USD
Consumer Products $785,719 USD
Chemicals $704,101 USD
Utilities (Power & Water) $643,250 USD
Metals/Natural Resources $580,588 USD
Package Shipping (Distribution) $28,000 USD

Source: Meta Group

Recommendations for Easing End-User Migration Projects

A new system should:

  • Offer a compelling value proposition and path to operational excellence
  • Minimize wiring
  • Preserve hardware investment
  • Preserve graphics and assist with or perform graphics conversion
  • Preserve control strategies and assist with or perform control strategy conversion
  • Minimize or eliminate downtime
  • Minimize training costs for a new system



Total Process Automation

Whether you are starting from scratch at a new facility or retooling an existing facility for growth purposes, you can trust that ECS has you covered.

  • Radically shorter schedules
  • Amazing flexibility for changing needs
  • Extremely efficient process execution
  • Highly focused operators

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TotalCare Support

TotalCare represents our concern not only for the process systems but also for the business or businesses those systems support.

Learn More About ECS Expert Support