SmartModernization ™


Different components of instrumentation and control systems, usually, have different lifetime. But what one should do, when one of the components fails? In most cases, the vendor just recommends to tear and replace the whole system. But is this an only option? Learn how Nexus IT Solutions SmartModernization™ may assist you in lifetime prolongation of existing control systems and IT infrastructure.

Nexus IT Solutions has a vast experience in smart modernization of computerized control systems, ensuring the system is capable to serve you for additional years without a major modification

SmartModernization™ methodology is based on layering concept, taken from object oriented programming and computer engineering, and carefully applied to industrial automation. The concept behind is quite simple

  1. Only the most problematic parts of the production line control system are upgraded or reconstructed
  2. Reconstruction is performed on one by one basis
  3. A complete functionality match is maintained between the legacy part of the control system and its successor.

For example, migration of process control application from legacy untrusted piece of hardware to a modern system would completely preserve system functionality and increase overall reliability of the system, with minimum effort, and virtually without any takedown.

What is your benefit?

Thorough modernization of an existing production line can increase efficiency and cut maintenance costs; however, such steps usually require significant investments. Moreover, the process of system modernization itself, once started, could take weeks, months, or even years (and frequently would require ceasing production for that time period). Do you have time and resources for that?

Consider a possibility to run your business for another 5-10 years without the need to spend money big time.. If running the same system for a longer period of time just could be possible, it would actually mean tens to hundreds percent ROI increase, saving significant funds which could be used for business development or other important tasks.

Another plus in favor of the smart modernization methodology derives from the sequental processing - at any project stage, one could revert a step back or postpone progress, without harming production.

With Nexus IT Solutions smart modernization, your production line will work overtime! 

So, how do we do that?

A typical production line comprises from the mechanics (such as servos, valves and instrumentation), production line controllers, a field bus or other communication technology, and a dedicated computer system, running a certain software. Unfortunately, as more complicated the system is, as shorter is it's life. Usually, the computing part just can't stand with mechanics.

Below, you may find a typical life time period for different components:

Component Recommended Replacement (years) Usual Replacement (years)
Mechanical parts 10-15 20+
Industrial Communications 10-15 20+
PLC 8-12 15+
Industrial Computers 4-8 8+
Regular Computers 3-5 6+
Dedicated OS
(such as Windows Embedded)
8 years end of support
12 years end of live
Usually cannot be installed on hardware other than original
Regular OS
(such as Windows XP)

4 years end of support
6 years end of live

Usually cannot be installed on recent hardware after entering end of live 
Dedicated software
(HMI / SCADA / process engineering)
2-4 Usually cannot be replaced due to dependencies on hardware and IO controllers

Moreover, the dedicated software, which sometimes was written especially for a specific deployment, relies on a certain OS, which, in turn, relies on the underlying hardware.

This sort of dependence makes a hard times for I&C department, since not rare are occations, in which the out-of-life OS cannot be run on new hardware.

By using innovative technologies, such as server and desktop virtualization, remote I/O and communication bridges, we eliminate the hard link between software and hardware, allowing easier spare parts replacement and comprehensive patch management.

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