Migration

Migration in industrial automation is the transfer of a control system, software or data from an old platform to a new one, while keeping the existing functions of the installation.

Control systems age faster than the machines they control. Manufacturers phase out older controller models and software versions, stop supporting them and stop producing spare parts for them. Old systems are also hard to connect to newer solutions and often do not meet current IT security requirements. Migration means transferring what runs on the old platform to new hardware or new software.

Migration may involve, among other things:

• PLCs: transferring the control program from an old controller to a new model,
• SCADA systems and HMI panels: transferring screens, alarms and settings to a new version or a different system,
• data: transferring recipes, historical data and settings to the new system,
• communication networks: replacing older communication methods between devices with new standards.

It is important that the installation works the same as before, or better, after the migration, and that operators can run it without lengthy retraining. That is why migration is usually carefully planned and tested before start-up, and the switchover is carried out during a planned shutdown, often in stages.

Migration usually concerns the control system, software and data, and can be part of a retrofit.

Example: A wet pet food plant has a line controlled by a PLC that is no longer supported by its manufacturer, and its SCADA system runs on an old computer with an outdated operating system. The plant commissions a migration: the control program is transferred to a new controller, the SCADA screens are recreated in the new version of the system, and the recipes and historical data are moved to a new database. Everything is tested in advance using simulation, and the switchover takes place during a weekend shutdown. On Monday, the operators are working on the new system, which looks and works just like the previous one, but is supported by the manufacturer and has spare parts available.