By Omer Qadri

In the realm of industrial automation, SCADA (supervisory control and data acquisition) and HMI (human-machine interface) systems play a pivotal role in overseeing and managing complex industrial processes. While legacy SCADA and HMI systems have been in installed for years, the ever-evolving technological landscape necessitates a critical evaluation of their modernization. 

It’s not uncommon for HMI SCADA systems to run to the point of failure, but is that really the best way to ensure future growth and stability? To stay competitive, companies must begin to evaluate how much their legacy systems may be costing them in terms of reduced productivity and long-term scalability. 

The Case for Legacy Systems: When Does It Make Sense to Hold On?

There are certain scenarios where retaining legacy SCADA and HMI systems proves to be a viable option: 

  • Cost-Effectiveness: Upgrading to a modern system may not be financially justifiable, especially if the existing hardware is still functional and the cost of replacement is substantial. 
  • Niche Industry Requirements: In specialized industries with limited hardware options, sticking with legacy systems may be the only feasible choice due to the lack of suitable alternatives. 
  • Extensive Legacy System Investment: The time and effort invested in developing and maintaining legacy systems may outweigh the perceived benefits of modernization.

The Case Against Legacy Systems: When Modernization Becomes Imperative 

Despite the scenarios, there are compelling reasons to consider modernizing legacy SCADA and HMI systems, particularly for critical infrastructure: 

  • Obsolescence Risks: As systems age, the likelihood of critical failures increases. Obsolete hardware may become irreplaceable due to discontinued production, and finding technicians with expertise in outdated systems can be challenging. 
  • Security Vulnerabilities: Legacy systems often lack ongoing security updates, leaving them susceptible to cyberattacks that exploit known vulnerabilities. 
  • Limited Functionality: Modern SCADA and HMI systems offer enhanced features and capabilities that legacy systems may lack, such as improved graphics, better trend analysis, recipe and batch control, advanced alarm management, and web-based accessibility. Modern HMI and SCADA systems provide a host of advantages, including enhanced data visualization, improved operator efficiency, remote access capabilities, and integration with enterprise systems. delivering comprehensive capabilities operator need beyond HMI / SCADA to include, shift handover & reporting, knowledge sharing, digitalization of work process & execution etc. 
  • Scalability/ Expansion of System: Scalability is not merely starting small and growing big. There are many dimensions to consider, and most are critical to true investment protection for the end user. Scalability is something that requires extensive planning; it must be part of the system design at the early stages. 

There are many dimensions to scalability, and all need equal organizational focus. 

  • Horizontal: System Integration. It involves integration with peer-level systems such as Historian, Workflow, Engineering Schematics, GIS, Documents/SOPs, and LIMS. 
  • Vertical: This involves integration with enterprise-level systems such as ERP, MES, Supply Chain Automation and Enterprise Asset Management. 
  • Functional: Grow Small Systems into Large Systems. It is all about gradual evolution, increased capacity, quality and energy efficiency. 
  • Multi-Site Expansion: Allow space for diversity of languages and localizations, without hampering usability and performance. Re-use engineering efforts and best practices across facilities and projects. 

AVEVA: Your Partner in SCADA and HMI Modernization

At AVEVA, we recognize the challenges and complexities involved in modernizing legacy SCADA and HMI systems. Our commitment to making the process as seamless as possible is evident in our solutions and support. We offer a wealth of resources, including free videos and tutorials, to guide you through the modernization journey. 

AVEVA Operations Control reduces obsolescence risk through backward compatibility, virtualized deployment options, and support for hybrid cloud architectures. In addition, AVEVA’s unique legacy of backward compatibility enables HMI applications built with AVEVA InTouch and AVEVA Edge software versions dating back to 1990s to be upgraded to latest version, allowing customers to modernize incrementally while protecting existing engineering investments. 

Omer Qadri is responsible for managing global product marketing strategy, subject expertise, and sales enablement for the operations software business at AVEVA. He joined AVEVA in 2016 as part of the portfolio marketing team with an emphasis on HMI/SCADA and operations control. Omer has been evangelizing the power of industrial software across process automation, enterprise software and SaaS customers. 

This content is sponsored by Aveva.