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Control System Modernization Control System Modernization

R.E. Mason helps industrial operations upgrade outdated automation systems to modern, secure, and scalable platforms. Whether you're running on legacy DCS, PLCs, or obsolete hardware, our modernization services help reduce downtime risk, boost cybersecurity, and pave the way for future digital transformation.

We partner with you to assess your current infrastructure, develop a phased or full migration strategy, and implement proven solutions using leading-edge tools and deep domain expertise.

Why Modernize Your Control System?

Digital transformation is accelerating. Control systems that are 10, 20, or even 30 years old can limit your ability to optimize processes, integrate data, and ensure secure operations.

Legacy control systems present a growing list of challenges:
  • Obsolescence & Unsupported Components
  • Cybersecurity Vulnerabilities
  • Technical Knowledge Gaps
  • Frequent Downtime & Maintenance Costs
  • Operational Inefficiencies
  • Inability to Integrate Modern Technologies
  • Maintaining Regulatory Compliance
With control system modernization, you gain:
  • Improved Reliability and Uptime
  • Enhanced Cybersecurity and Compliance
  • Integration with Analytics, Remote Monitoring, and IIoT
  • Greater Operator Effectiveness
  • Scalability and Flexibility
  • Long-Term Sustainability
Tailored Strategies. Minimal Disruption.

Tailored Strategies. Minimal Disruption.

We work with your team to determine whether a full migration, phased upgrade, or hybrid approach best aligns with your:

  • Downtime tolerance
  • Budget
  • Operational complexity
  • Risk profile

With extensive experience in brownfield facilities, we focus on maintaining operational continuity, validating interdependencies, and ensuring installation readiness.

Our Modernization Approach

We don't just replace hardware, we deliver a structured, value-driven approach that reduces downtime and disruption

  • Current State Analysis
  • Business Case Development
  • Automation Readiness Review
  • Target System Design
  • Network, Security, and Compliance Planning
  • Integration Strategy
  • Control Logic Conversion / Replacement
  • Data Migration & Signal Mapping
  • Operator HMI Rebuilds
  • Staging, Simulation & Factory Acceptance Testing
  • Cutover Planning and Execution
  • Operator Training and Change Management
  • Hypercare Services
  • Monitoring and Tuning
  • Alarm Rationalization
  • Ongoing Optimization & Managed Service
  • Complete System Documentation
  • On-going and Customized Operator Training

Tools That Set Us Apart

By combining field-proven expertise with cutting-edge technology and trusted industry collaboration, R.E. Mason delivers modernization tools that are efficient and reliable.
REVAMP with Generative AI: Automatically translates legacy configurations into DeltaV-ready logic, significantly reducing manual effort, risk, and timelines.​
Simulation & Staging Environments: Validate functionality and system readiness, train operators, and test performance before live deployment to ensure a seamless installation.
Comprehensive FAT & Documentation: Customer-centric Factory Acceptance Testing ensures full system familiarity, readiness and confidence prior to site deployment.​
Assessing a legacy control system and developing a tailored migration plan requires a structured, consultative approach that balances technical analysis with business priorities.  ​
 
  • Discovery & Stakeholder Alignment​
  • System Inventory & Technical Assessment​
  • Risk & Impact Analysis
  • Migration Strategy Analysis utilizing Generative AI
  • Cost Estimate & Business Case​ Execution & Resource Planning
Our engineers have experience modernizing a wide range of legacy systems to DeltaV and other Emerson solutions, include: ​
 
  • Allen-Bradley / RSLogix​
  • Siemens
  • ABB
  • Honeywell TDC & Experion
  • Foxboro I/A​
  • NovaTech D/3​
  • And Others
Real Results. Real Lessons Learned.

Real Results. Real Lessons Learned.

"A control system migration is far more than a technical upgrade—it’s an operational transformation. Success starts with planning, stakeholder engagement, and having the right partner." 
 

Top Lessons from Years of Migrations:​

  • Early stakeholder planning and alignment avoids rework and delays​

  • Involving operations and maintenance early improves success​

  • Strategic hardware procurement avoids schedule risks​

  • Phased migrations lower operational disruption​

  • Change management is as critical as engineering​

  • Backups and contingencies are non-negotiable


The Risk Isn't Modernization. It's Inaction.

Delaying a migration may seem like a safe option, until it's not. As legacy systems fail, options become limited, costs grow, and risks compound.

Let’s future-proof your operations. Together.

  • Contact Us
  • Schedule a Site Walkdown​

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