Many industrial facilities are still operating with legacy Honeywell TDC 3000–based control systems that have reached the end of their lifecycle. These environments face growing challenges:
Obsolescence
Aging hardware and unsupported operating systems increase exposure to operational and cybersecurity risks.
Limited Flexibility
Legacy architecture restricts the integration of modern control strategies and advanced visualization.
Scalability Constraints
Outdated network design and controllers limit system growth and adaptability.
Operational Continuity
Any migration must be executed without disrupting ongoing production in high-stakes industrial environments.
Champion designed and executed a seamless Honeywell Experion PKS C300 and Triconex SIS modernization strategy, leveraging a phased migration approach:
Controller & I/O Upgrade
Legacy controllers were replaced with Experion C300 hardware, while robust PMIO was retained for cost efficiency and continuity.
Control Logic Migration
Critical CL code was converted into Experion Control and Sequential Control Modules, ensuring operational equivalence and improved maintainability.
Triconex SIS Modernization
Legacy Triconex safety logic was converted to Triconex CX, including migration of hundreds of SIS I/O points, ensuring compliance with modern safety standards and maintaining functional safety integrity.
HMI Modernization
Operator graphics were re-designed to Experion standards, applying Champion’s HMI guidelines for improved usability, alarm visualization, and situational awareness.
Network & Security Enhancements
Fault-Tolerant Ethernet (FTE) and Windows domain migration strengthened reliability and cybersecurity posture.
Comprehensive Testing
Factory and Site Acceptance Testing, along with simulation of both process control and SIS logic, ensured risk-free deployment.12 Months
Zero Disruption Migration
Operations continued uninterrupted through a carefully planned cutover.
Improved Reliability
Fault-tolerant architecture and modern C300/SIS controllers enhanced system performance and safety.
Enhanced Operator Experience
Standardized, user-friendly graphics improved visibility and reduced operator workload.
Future-Ready Foundation
Scalable Experion PKS and Triconex CX architecture with secure network design created a platform for ongoing digital transformation and cybersecurity posture improvements.
Champion brings unmatched expertise in modernizing control and safety systems without operational disruption:
Multi-Platform Expertise
Skilled in both legacy DCS platforms and modern Experion PKS, as well as Triconex SIS modernization.
Risk-Aware Execution
Proven methodology for executing migrations in live operating environments.
Optimized Integration
Ability to retain existing I/O infrastructure while seamlessly introducing modern control and safety strategies.
Client Partnership
Transparent communication, operator training, and collaborative design reviews ensure alignment from concept through commissioning.