Project Brief

Control System Modernization

Petrochemicals, Manufacturing // Texas


  • The Challenge

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Outdated network design and controllers limit system growth and adaptability.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.

  • Our Solution

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.
  • Project Timeline

12 Months

  • The Results
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.

  • The Champion Advantage

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.

article

Virtualizing the Future

 Learn more
solution

Digital Transformation

 learn more
Read More
Project Brief

Multi-Site OT Cybersecurity Assessment

Specialty Chemicals, Manufacturing


  • The Challenge

The client sought to gain deeper visibility and control across multiple industrial facilities. While each facility had its own systems and processes in place, there was a clear opportunity to enhance standardization, improve documentation, and align cybersecurity practices across the broader OT environment.

Key focus areas included:

  • Establishing a consistent view of OT assets across all facilities
  • Improving clarity around existing network architectures
  • Identifying opportunities to strengthen and unify cybersecurity policies and controls

With this assessment, the client aimed to lay a stronger foundation for long-term resilience and scalable security management.

  • Our Solution
Asset Inventory and Lifecycle Analysis

Champion conducted a thorough inventory of OT assets across all sites, capturing:

  • Detailed information such as make, model, and operational condition
  • Lifecycle stage and support status
  • Physical location and criticality
Network Topology Mapping

We mapped each site’s Process Control Network (PCN), delivering:

  • Accurate, facility-specific network diagrams
  • Visibility into asset interconnectivity and data flow
  • Identification of segmentation gaps and vulnerability points
OT Cybersecurity Gap Assessment and Remediation Planning

Our team performed an in-depth gap analysis and developed a tailored remediation strategy. Key deliverables included:

  • A prioritized list of findings ranked by criticality and operational risk
  • High-level cost estimates for remediation at each facility
  • A strategic roadmap aligned with NIST CSF and industry best practices
  • Project Timeline

4 Months

  • The Results

Champion provided a comprehensive view of the client’s multi-site OT environment, highlighting both areas of strength and opportunities for improvement. Results included:

  • Detailed documentation of assets and network architecture
  • Clear recommendations to formalize cybersecurity policies and procedures
  • Actionable improvements to strengthen monitoring, analytics, and system defenses

We also mapped the client’s position within the NIST Cybersecurity Framework maturity model and delivered prioritized, cost-estimated recommendations. This enabled the client to confidently invest in the most impactful improvements and advance their OT cybersecurity program with clarity and direction.

  • The Champion Advantage
OT Application Expertise

Champion brings deep expertise of both operational technology (OT) environments and enterprise-level network architectures. Our team bridges the IT/OT knowledge gap by:

  • Applying strategies that align with enterprise-wide policies while addressing the unique challenges of OT environments
  • Combining technical depth with hands-on operational experience to reduce risk and improve system resilience
Optimized Integration

Whether upgrading legacy platforms or implementing new technologies, Champion delivers seamless, cost-effective integration. Our proven approach ensures:

  • Interoperability across modern and legacy systems with support for multi-vendor environments

  • Minimal operational disruption through careful planning and phased execution

  • Sustainable, scalable solutions that deliver long-term value and adaptability

article

Securing Legacy OT Systems

 Learn more
solution brief

Disaster Recovery

 download
Read More
Project Brief

PCN and DMZ IDC Upgrade

Petrochemicals, Manufacturing // Louisiana


  • The Challenge
Outdated Virtual Environments

Existing datacenter hardware had reached end-of-life, creating limitations in performance, maintainability, and vendor support.

Unscalable System Architecture

The legacy PCN and DMZ systems were built on unupgradable physical appliances, unable to support growing demands or modern applications.

Minimal Redundancy and Recovery

The prior environment lacked virtualization-level failover, reducing the ability to maintain continuity during failures or maintenance.

Unsupported OS and Applications

Critical virtual machines were operating on unsupported platforms, limiting cybersecurity alignment and software patching options.

Mixed Configuration and Oversight

Disparate domain structures and unmanaged system updates posed obstacles to centralized control and consistent operations.

Zero-Disruption Requirement

Upgrades had to be completed without interrupting plant operations, requiring parallel validation and a risk-informed deployment plan.

  • Our Solution
Virtual Infrastructure Modernization

High-availability PCN clusters and standalone DMZ servers were implemented using ESXi hosts and Dell storage arrays, managed via vCenter.

Network Architecture Redesign

Cisco Catalyst switches provided redundant paths, VLAN segmentation, and firewall integration to enhance reliability and zone isolation.

Factory Acceptance & Site Testing

In-house FAT and site SAT validated configuration and failover. Cutover was completed with zero operational impact.

VM and Software Configuration

Over 20 virtual machines were configured to support:

  • Real-time industrial data collection and historian interfaces
  • Antivirus and centralized patching services
  • Rotating equipment condition monitoring and diagnostics software
  • Control system trace and event logging tools
  • Active Directory domain control and backup systems
  • Project Timeline: 8 Months
  • The Results
Improved Uptime

Cluster failover and HA ensure operational continuity and quick recovery.

Stronger Cybersecurity Posture

Supported OS versions, AV/patching agents, and segmented VLANs align with OT best practices.

Streamlined Management

Domain integration, backup validation, and centralized vCenter simplify operations and updates.

Scalable Architecture

The system is designed for future expansion, remote diagnostics, and lifecycle planning.

  • The Champion Advantage
Seamless Integration

Champion delivered a unified virtual infrastructure, covering computer, networking, and virtualization, with end-to-end accountability from design through commissioning.

Client-Centered Execution and Support

From risk-informed cutover strategies to on-site support, Champion aligned closely with operational constraints to execute without disruption to any critical processes.

Future-Ready Foundation

The virtual architecture supports future growth, secure access, centralized patching, and improved OT visibility, positioning the client for ongoing digital transformation.

OT Application Expertise

With deep experience in OT Applications such as historian integration, rotating asset diagnostics, trace/event logging, and OT endpoint security, Champion ensured each application was migrated, validated, and optimized in the new environment.

Smarter Commissioning, Faster Execution

Champion’s structured FAT, SAT, and operator validation approach delivered efficient deployment with confidence in operational readiness.

Curious what Champion can achieve for you?

contact us
article

Virtualizing the Future

 Learn more
solution brief

Industrial Data Centers

 download
Read More
Project Brief

Industrial Data Center Upgrade

Oil & Gas, Midstream // Southeast Texas


  • The Challenge

Legacy data center hardware had reached end-of-life, limiting system reliability, scalability, and vendor support options.

Obsolete Windows environments prevented the application of critical patches and updates, impacting compliance and system stability.

Outdated versions of FactoryTalk and historian software introduced performance bottlenecks and integration challenges with modern platforms.

A fragmented domain and workgroup configuration made it difficult to enforce consistent user policies or manage authentication centrally.

Limited VLAN segmentation reduced network visibility, increased broadcast domain congestion, and created barriers to secure zone management.

The absence of high-availability mechanisms and VM mobility increased risk during maintenance windows and system transitions.

The migration needed to occur without interrupting operations, requiring a carefully sequenced cutover plan and parallel runtime verification.

  • Our Solution

Both data center environments were rebuilt with fully virtualized, high-availability platforms. Core control system applications, historian nodes, and Windows services were migrated to domain-managed virtual machines for greater scalability and centralized control.

Switching infrastructure was upgraded to support segmented VLANs for management, storage, and control traffic. Routed failover between sites provided redundancy and improved network performance.

OT applications including FactoryTalk View SE, Linx, Alarm & Event, and Historian services were upgraded to current versions. Engineering and operator workstations were refreshed with pre-configured toolsets for faster deployment and user readiness.

A structured deployment approach included Factory Acceptance Testing (FAT), parallel HMI validation, and a staged cutover. Snapshot backups and rollback procedures ensured system continuity throughout.

  • Project Timeline: 6 Months
  • The Results

The modernized OT systems delivered key advantages. Redundant systems ensured uptime and operational continuity, while network segmentation and supported platforms strengthened cybersecurity. Centralized control simplified management, and modern infrastructure provided fast recovery and failover.

  • The Champion Advantage
Seamless Integration

A unified solution across virtualization, networking, and software eliminated the need for multiple vendors.

Client-Centered Execution and Support

Staged cutover, clear documentation, and on-site training ensured a smooth transition with minimal disruption.

Scalable and Future-Ready

The upgraded infrastructure supports digital growth, remote access, and enhanced OT visibility.

Smarter Commissioning, Faster Execution

Champion’s risk-informed approach, with FAT, SAT, and operator validation, enabled efficient deployment and handoff.

Ready to elevate your operations?

contact us
article

Securing Legacy OT Systems

 Learn more
solution brief

Disaster Recovery

 download
Read More
Project Brief

On-Process Control System Migration

Oil & Gas, Upstream // Gulf of Mexico


  • The Challenge

The outdated Control System Infrastructure lacked modern performance enhancements and advanced features.

Obsolete Process Control Network appliances and architecture lacked scalability and posed risks to both operations and security.

Unsupported Windows operating systems increased exposure to cyber threats and compliance issues.

A live system upgrade required a structured approach to ensure zero impact on ongoing operations.

  • Our Solution

On-Process Control System Migration (OPM) to the latest Honeywell Experion® PKS software, incorporating critical system components such as enterprise models, trends, control modules, SCADA points, and operator graphics.

PCN Network Redesign to implement Fault-Tolerant Ethernet (FTE) with the latest Cisco network appliances, ensuring enhanced reliability and redundancy.

System Architecture Upgrade, transitioning PCN servers and operator stations from a Microsoft Workgroup to a Domain, improving security and access management.


Comprehensive Factory Acceptance Testing (FAT) of integrated software and hardware to mitigate risks before deployment.

On-Process Field Installation & Commissioning, ensuring a seamless transition to the upgraded system while maintaining operational continuity.

  • The Results

With a comprehensive implementation plan and rigorous testing, the solution was commissioned without operational disruption. This seamless transition enabled the client to operate the upgraded system with enhanced reliability, security, and performance, ensuring long-term operational efficiency.

  • The Champion Advantage
Seamless Integration

Delivery of a turnkey solution integrating Honeywell Experion® PKS, FTE networks, Windows domain migrations, and third-party systems eliminated the need for multiple vendors and delivered a cohesive, cost-effective solution.

Client-Centered Execution and Support

Clear communication, hands-on operator training, and a well-documented transition plan empowered facility operations for long-term success.

Scalable and Future-Ready

Solutions designed with a technical and operational cutover plan ensured a disruption-free migration. The FTE network and Windows domain built a flexible foundation for future growth and cybersecurity enhancements.

Smarter Commissioning, Faster Execution

Continuous engagement with our project team from design through commissioning minimized risks, streamlined troubleshooting, and ensured a seamless installation.

article

Securing Legacy OT Systems

 Learn more
solution brief

Disaster Recovery

 download
Read More