Modernize SCADA without taking the line down.
Salem moves unsupportable DOS, HMI, and SCADA systems onto a modern Ignition platform — proving the new system against live production before cutover. Zero downtime, and none of the process logic built over decades is lost.
End-of-life control systems don’t fail politely.
The longer an unsupportable SCADA system runs, the narrower your options get — and the fewer people are left who can keep it alive.
$100Ks / hr
Cost of downtime
Unplanned outages on legacy control systems are measured in hundreds of thousands of dollars per hour.
6–8 wks
Test windows
Between the planned outages where you can safely test changes — so every modernization attempt carries real risk.
Ended
Vendor support
DOS HMI, Indusoft, and GE iFIX on aging Windows: no upgrade path, and a shrinking pool of people who can maintain them.
Shadow Mode proves the new system before you switch.
1
We build the new Ignition system and feed it the same live process data as the system in production.
2
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.
4
The result: a modern platform goes live with zero production downtime and no surprises.
Why it matters
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.
Four phases.
Fixed deliverables.
Every engagement follows the same method — so you always know the scope, the risk, and what you’ll receive at each stage.
01
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.
02
Rebuild
We rebuild your interfaces on Ignition 8.x and convert legacy logic to maintainable Python and C#, matched to legacy parity.
03
Shadow Mode
The new system runs in parallel with live production and is validated against real operations before a planned, zero-downtime cutover.
04
Train & Go Live
We hand over a supportable system with full operator documentation, on-site training, and go-live support.
From end-of-life to Ignition.
Assess & Plan
DOS HMI (PCWS), Indusoft Web Studio, GE iFIX & comparable end-of-life HMI/SCADA
Ignition 8.x on current Windows infrastructure
Control logic
Legacy logic, including FORTRAN
Maintainable Python & C#, preserving process behavior
Architecture
Isolated Level 2 supervisory control
ISA-95 Level 2 with a path to quality, reporting & enterprise data (Levels 3–4)
A Tier 1 industrial manufacturer retired three legacy platforms — without losing a minute of production.
100%
Uptime through cutover
Zero
Process logic lost
3
Legacy platforms retired
Tell us what’s running on your plant floor.
We’ll help you scope a path off it — starting with a fixed-fee assessment, and without taking production offline.