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Proven Results

Modernizing a Legacy DCS in a Live Operating Facility

March 24, 2026

The Challenge

A large Western Canadian industrial facility was operating on a legacy control system approaching end‑of‑support. The aging platform increased operational risk, limited cybersecurity resilience, and made system maintenance increasingly difficult. A full system replacement was not feasible due to production constraints and the risk of extended downtime.
The Solution

The Solution

Spartan Controls partnered with the customer to develop a phased control system modernization strategy that allowed the facility to remain operational throughout the project. The approach focused on modernizing core control infrastructure while preserving existing field devices, reducing risk and capital impact. Cybersecurity and alarm performance were addressed as part of the system architecture, ensuring long‑term stability and compliance.

The Value

  • Reduced operational risk associated with unsupported legacy components
  • Improved system reliability and availability in a live operating environment
  • Lowered cybersecurity exposure through modernized architecture
  • A future‑ready control platform capable of supporting optimization and analytics initiatives