Project Brief

Control System Modernization

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Outdated network design and controllers limit system growth and adaptability.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

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Project Brief

On-Process Control System Migration

  • 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.

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Blog

Cisco Catalyst 2960 End of Life: What It Means for OT Environments

🚨 Cisco Catalyst 2960 Switches: End of Life & What It Means for OT Systems

If you’re operating industrial control systems, chances are Cisco Catalyst 2960 switches are buried somewhere in your infrastructure. These reliable workhorses have long supported OT environments—but Cisco has officially announced their End of Life (EOL).

For facilities relying on these switches for SCADA, PLC, or DCS networks, the implications are serious:
🔒 Increased cybersecurity risk
⚠️ Unplanned downtime
💸 Rising replacement costs

❓What Does EOL Mean for Catalyst 2960?

Cisco’s EOL designation means that the Catalyst 2960 switches will:

  • ❌No longer receive software updates or critical security patches 
  • 📞No longer be supported under standard Cisco TAC
  • 🧩Become harder (and pricier) to source due to limited hardware availability

In OT environments, this creates major concerns such as: 

  • 🔐Incompatibility with modern security standards 
  • 🔧Lack of support during failures or cyber incidents 
  • 🛑Disruptive outages caused by aging hardware 
  • 🛑Growing attack surface due to outdated firmware 

⚠️The Risk of Doing Nothing

Sure, the 2960 might still “work”…
But in regulated or mission-critical facilities, relying on unsupported hardware is a liability.
These switches are often deeply integrated—meaning failure could affect production, safety, and compliance.

🛠️Champion’s OT Mitigation Strategy

Our team brings deep domain expertise in ICS networks and zero-disruption migration planning. Our strategy is built for operational continuity:

1️⃣OT Network Discovery

Full network audit to locate 2960s, identify dependencies, and assess criticality.

2️⃣Lifecycle and Risk Analysis

Prioritization using OEM lifecycle data, operational impact, and supportability.

3️⃣Replacement Roadmap

Phased rollout using industrial-grade, Cisco-approved switches ensuring: 

  • Compatibility with your OT protocols 
  • Segmentation and VLAN design 
  • Ruggedization for harsh environments

4️⃣Secure Network Design and Hardening

We go beyond replacement to modernize your OT network:

  • ISA/IEC 62443 alignment
  • Security Zone segmentation
  • VLAN/firewall rules
  • Zero Trust principles

5️⃣Project Execution and Commissioning

Planned and executed by our experienced OT teams during low-risk windows, minimizing downtime and maintaining system integrity.

6️⃣Ongoing Support

Post-upgrade monitoring, health checks, and managed support for sustained reliability.

🏆Why Champion?

With decades of control system integration experience, we’ve successfully delivered secure migrations across:

  • 🛢️ Oil & Gas
  • 🧪 Chemicals
  • ⚡ Utilities
  • 🏭 Manufacturing
  • 🚢 Marine & Terminals

In these environments, downtime isn’t an option—and safety is non-negotiable.

💡Final Thoughts

EOL for the Catalyst 2960 isn’t just a hardware sunset. It’s a strategic opportunity to strengthen your OT network’s security, resilience, and performance.

Let’s modernize your network—on your terms.

Let's collaborate.

Schedule a no-cost consultation today.

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Securing Legacy OT Systems

Legacy operational technology (OT) systems are still heavily relied on by much of the industrial and critical infrastructure sectors. As digital transformation becomes the new norm, these legacy systems present complex challenges to implementing vital cybersecurity measures.

The Challenge

Legacy systems may include components that are decades old– meaning their designs never accounted for modern cyberthreats and the implications of digital convergence.

As these systems reach end-of-life (EOL), lack of updates and patches, discontinuation of vendor support, and incompatibilities with emerging tech compound the risk of critical disruption.

Best Practice Solutions

Network Segmentation

By isolating critical systems, you can reduce the spread of cyberattacks and limit the potential impact of security breaches.

Cybersecurity Audits

Regular reviews of cybersecurity policies and controls can identify vulnerabilities, ensure regulatory compliance, and uncover inefficiencies.

Access Control

Enforcing strong authentication, authorization, and accountability mechanisms ensure only the necessary personnel have access to critical systems.

Incident Response Planning

Developing and routinely testing an incident response plan enables the efficient identification and mitigation of cyber incidents.

The Takeaway

Integrating new tech into legacy OT systems can seem daunting, but with an informed understanding of the risks and a commitment to implementing best practices, you can protect your organization’s critical systems and stay competitive in the digital age of industry.

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Choosing the Right Control System for Your Facility

Is your control system approaching its end-of-life product lifecycle?
Does your system rely on replacement parts that are increasingly harder to find?
Is it difficult to find personnel experienced with your control system?
It may be time to upgrade.

How do you choose the right system?

When you have identified that it’s time to upgrade your control system, you want to explore all the options that are available to you. It is especially important to find a control system that best fits your application. For example: if you need to upgrade a controller, you will avoid upgrading the entire control system.

Some manufacturers’ control system platforms offer a variety of upgrade and migration solutions and strategies. For some end users, there are migration strategies that may be a better solution than a complete upgrade. In other cases, a complete system upgrade may be the answer. Most of the time the best solution is somewhere in between. Understanding your unique needs and expectations is vital to choosing the proper system. This can be a challenging task if you don’t have the required information.

Some things to consider:

  • Lifecycle of Existing Assets
  • Pros/Cons of Technology Solution Options
    • Evaluated by an unbiased party with hands on experience
    • How will the technology solution better enable you to meet industry requirements and best practices such as safety and cybersecurity (ISA, NFPA, CISA)?
  • Feasibility and Impact of the Solution
    • Technology solution and strategy
    • Potential downtime and risk mitigation
  • Maintenance and Support
    • Effort required to maintain the system
    • Training of staff to maintain the system
    • Identify established partners to provide timely support
  • Total Cost of Ownership
    • Evaluated by an unbiased party with hands on experience

We’re here to help.

Finding a system that meets your needs and understanding how it will function and grow with you can be a challenge. Champion's team specializes in leading clients through the process of choosing a control system that is right for their specific needs – and their budgets. As part of our process, we will work with your team to define your goals and expectations, conduct an assessment, and recommend the best, unbiased solution that aligns with your goals. We can bring your control system from the past to the present while you plan for the future.

Let's collaborate.

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The Hidden Costs of Your Legacy Systems

“My old control system is still hanging in there. How can I justify a costly replacement to management?” This is an age-old question, to which many believe: “If it ain’t broke, don’t fix it.” However, when it comes to Industrial Control Systems (ICS), this approach is often the riskier and costlier route for facilities.
The answer lies in Total Cost of Ownership (TCO) – a method of engineering, economic, and financial analysis. TCO aims to consider all of the direct and indirect costs related to a product over its lifetime. The TCO of your car isn’t just the purchase price, but all the related costs over the time you own it: gas, financing, insurance, maintenance, depreciation, and more. The same approach can be applied to a control system over its lifetime.

Common Hidden Costs

Maintenance

The cost of maintaining legacy systems grows exponentially with age. This is due to increased routine problems, along with added system complexity from customization and changes. Over time, updates become more time-consuming and costly.

Talent

In parallel with maintenance costs, talent costs are much higher on a legacy system. Not only are the costs exorbitant in man-hours, but unlike on newer systems, they often require skill sets that are expensive and difficult to find.

Support

As proprietary legacy systems reach a point of limited or discontinued vendor support, the costs of support begin to soar. Tie this to increasing talent costs for external support, longer support response times, and – dare we say it – interruptions in production that affect your bottom line at its core.

Compliance

With industry regulations continually changing, the cost of keeping legacy technology in compliance can be burdensome. Even more costly are the risks of noncompliance, with penalties or fines adding to your Total Cost of Ownership.

Lost Revenue Potential

Without newer features such as mobile data access, or the ability to gather and act via analytics tools, your plant operates on inefficient processes, lower production output, and results in a dwindling bottom line.

New Tech, New Benefits

Implementing new technology can bring a wealth of benefits, from risk reduction and meeting heightened regulatory standards to better decision-making and improved efficiency. Technology of today enables facilities to be more agile, innovative, and cost-effective in an ever-evolving climate.

Concerns of process interruptions can most times be eliminated using well-planned migration approaches, and increased security can alone make the switch a worthwhile investment. Champion’s Certified Cybersecurity Experts are trained in the latest ISA/IEC 62443 standards for Cybersecurity, ensuring your new system benefits from the most current, comprehensive safeguards.

At some point, legacy technology becomes a barrier to daily operations, business stability, and overall growth. By knowing the true cost of running legacy systems, industry leaders can see the clear return on investment (ROI) of embracing new technology and its upward-driving effects on your bottom line.

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