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Control System Modernization Control System Modernization
$2B+ per year in avoidable equipment damage from abnormal situations.

$2B+ per year in avoidable equipment damage from abnormal situations.

Modernizing process safety systems in operating facilities is complex. Aging SIS platforms, increasing regulatory pressure, and limited outage windows make “rip and replace” approaches unrealistic.

Spartan Controls helps asset‑intensive operations modernize process safety systems in a way that reduces risk, protects availability, and supports long‑term operational stability—without disrupting production.

Why Modernization Matters

Unscheduled shutdowns can cost heavy process industries 2–5% of annual production, with poor alarm management a major contributor to abnormal situations and equipment damage.

The Challenge

Legacy Control Systems Nearing End of Life
Upgrade Risk and Downtime Concerns
Alarm Floods and Operator Overload
Regulatory and Safety Compliance Pressures
A practical approach to process safety modernization

A practical approach to process safety modernization

Effective process safety modernization is not just about new technology. It requires a disciplined, phased approach that balances safety, availability, and operational realities.
Spartan Controls supports process safety modernization by:
 
  • Assessing current SIS and control system lifecycle risk
  • Aligning safety modernization with operational constraints
  • Planning phased upgrades that minimize downtime
  • Supporting safe transitions across people, processes, and technology
The result is a modernization path that improves safety integrity without introducing new operational risk.

System Migration & Modernization Solutions

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Dow MOD5
Dow MOD5
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Safety Instrumented Systems
Safety Instrumented Systems
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Modernizing a Legacy DCS in a Live Operating Facility
10–25% reduction in unplanned downtime, equivalent to $500K–$2M+ annually

Modernizing a Legacy DCS in a Live Operating Facility

A Western Canadian industrial facility was operating a legacy control system nearing end‑of‑support, increasing operational and cybersecurity risk. A full system replacement was not possible due to production constraints.

Spartan delivered a phased modernization strategy that upgraded core control infrastructure while keeping the facility online and preserving existing field devices.

Read the Case Study
Phased Modernization to Reduce Operational Risk
20–40% reduction in nuisance alarms, improving operator effectiveness

Phased Modernization to Reduce Operational Risk

Multiple aging control platforms caused alarm fatigue, inconsistent system performance, and heavy reliance on legacy system expertise.

Spartan developed a multi‑year modernization roadmap aligned with planned outages, prioritizing high‑risk systems first.

Read the Case Study

Take the Next Step

Connect with a Specialist
Connect with a Specialist

Connect with an expert who understands Western Canadian industrial operations.

Connect with a Specialist
Explore Secure & Stable Operations
Explore Secure & Stable Operations

Discover how Spartan helps industrial operations reduce risk, improve reliability, and run predictably.

Build a More Secure, Stable Operation

Stability doesn’t come from new technology alone, it comes from disciplined execution and governance

 

Our Solutions

DeltaV Alarm Operations
Emerson
Alarm Management
DeltaV Alarm Operations
DeltaV Alarm Mosaic
Emerson
Alarm Management
DeltaV Alarm Mosaic
DeltaV Edge Environment
Emerson
Security & Networks
DeltaV Edge Environment

The Path to Secure & Stable Operations

Control System Modernization
Control System Modernization
OT Cybersecurity
OT Cybersecurity
Advanced Process Control
Advanced Process Control
Operator Performance
Operator Performance
Secure Data Integration
Secure Data Integration

Insights

Control & Safety Systems

PLC Modernization Solutions for Automation Managers - How to Choose the Right One for Your Plant?

August 4, 2020
Spartan’s Modernization & Migration Solutions team will help you identify the most appropriate and cost-effective modernization plan for your site, utilizing the tools & technology to match your schedule, budget and plant standards.
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Digital Transformation

OnePlant™: The Best Integration Is No Integration

July 29, 2024
Spartan Controls' OnePlant™ solution revolutionizes industrial automation by eliminating integration complexities, providing seamless access to all plant data through Emerson’s DeltaV DCS, and enhancing operational efficiency and cost-effectiveness.
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Digital Transformation

Advanced Process Control for Ore Processing Improves Throughput, Efficiency and Sustainability

August 25, 2022
A practical, experienced approach to advanced control in mineral processing. "The ability to shave even a few percentage points off total energy consumption per ton can result in huge increases to a facility's bottom line, along with substantial improvements to efficiency and sustainability."
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Digital Transformation

When to Update your Plant Graphics and How to Get it Funded

May 19, 2021
Don’t let outdated operator interfaces be a barrier for your organization’s business objectives. Increasingly, we are being asked to prepare for the challenges of a changing digital workforce, remote work locations, and data portability. Empower intelligent decision-making through human-machine interface improvements while also optimizing the user experience and using technology to aggregate data before there is a demand for it. Here are some strategies to get that long overdue HMI overhaul off the ground.
Read More