SCADA Modernization Without Taking the Line Down
Salem moves unsupportable DOS, HMI, and SCADA systems onto Ignition, our preferred modern platform, proving the new system against live production before cutover. Movicon and Rockwell FactoryTalk are available where your site standards require them.
The real cost of running end-of-life control systems
The longer an unsupportable SCADA system runs, the narrower your options get, and the fewer people. are left who can keep it alive.
$100K+/ hr
Unplanned outages in legacy control systems routinely cost more than six figures per hour in lost production.
6–8 wks
The typical gap between planned outages where changes can be safely tested, which is why every modernization attempt carries real risk.
Ended
How Shadow Mode proves the new system before cutover.
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We build the new Ignition system and feed it the same live process data as the system in production.
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It runs in parallel, in the shadow of the real system, while we validate its behavior against live operations.
3
Only once it matches do we cut over, on a planned window, with a rollback plan ready.
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The result: a modern platform goes live with zero production downtime and no surprises.
End-of-life control systems don’t fail politely.
Either you take the line down to switch systems, or you keep running something you can no longer support. Shadow Mode removes that choice. The new system earns its place in production before it ever takes control.
What we preserve
Your process logic.
Decades of proprietary control logic, even FORTRAN, is rewritten as maintainable Python and C#. Preserved, not discarded.
follows the same method, so you always know the scope, the risk, and what you’ll receive at each stage.
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Assess & Plan
We audit your control environment and scope a phased path that preserves every operator function, delivered as a roadmap and a fixed-price proposal.