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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.

Request an Alarm Health Check Read the Case Study

The Challenge

Legacy Control Systems Nearing End of Life
Upgrade Risk and Downtime Concerns
Alarm Floods and Operator Overload
Regulatory and Safety Compliance Pressures

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

 
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.

Modernization & Migration Solutions

Dow MOD5
Safety Instrumented Systems

Start with a conversation about your safety system lifecycle

Request an Assessment

Get a clear picture of your operational risks, and the fastest path to improved uptime.

Talk to a Spartan Controls Process Safety Specialist
Talk to a Spartan Controls Process Safety Specialist

Discuss your current safety systems, lifecycle risks, and modernization options.

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

Secure. Visible. Governed. Stable

Modernization & Process Safety
OT Cybersecurity
Advanced Process Control
Secure Data Integration
Control & Safety Systems

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Digital Transformation

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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.
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