A SCADA migration goes wrong when the new system goes live with problems nobody knew the old one had. We avoid that by copying first and improving second, with both systems running side by side until each area is proven.
We rebuild the existing screens as they are before redesigning anything. The old screens are the specification, and much of how they behave is not written down anywhere. Once an area matches and its data, scaling and flow are checked, we improve it, standardize it across areas, and only then add new capability.
Every plant has someone who knows why a button is where it is and what an operator expects to see after pressing it. We work alongside that person for each area, because that knowledge is not in the old project files.
The old screens only show the tags someone chose to display. The tag inventory comes from the PLCs and the OPC server, so values the old system logged or alarmed on without showing them are not lost.
Ignition watches the same devices as the old system while an area is being proven. Before both systems can write to a device, we decide which one is allowed to, so two systems never send conflicting commands. We also check each rebuilt screen for values that never populate, which is how an unmapped tag shows itself.
Each area moves when it is ready: the order of work, the downtime window, how to roll back and who signs off are written down first. Operators move to screens they already recognize, then get the improvements.
Ignition is licensed by the server with unlimited clients, so screens can go on more stations, tablets and phones without per-seat licenses. Perspective runs in a browser, so operators can reach their screens from the devices they already carry. Training on your own system helps the change stick.
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