Overview
A municipal water authority was running on aging Siemens S5 hardware that was increasingly hard to source and impossible to extend.
Spare parts for the S5 platform were end-of-life, and the original logic was undocumented. The plant could not afford downtime, so the migration had to happen in phases while treatment continued uninterrupted.
We reverse-engineered the existing S5 program, rebuilt it as maintainable S7-1500 logic, and modernized the SCADA layer. A phased cutover schedule moved one process area at a time, with each stage validated against the live plant before the next began.
Full migration completed with zero unplanned downtime
Modern, supportable hardware and documented code base
SCADA visibility improved for operators and maintenance
They moved us off S5 without a single interruption to treatment. That was the whole ballgame for us.
Operations Supervisor · Municipal Water Authority