Many industrial facilities continue to operate reliable Siemens S7-300 and S7-400 control systems. However, ageing hardware, legacy STEP 7 software and changing support requirements can make these systems increasingly difficult to maintain and modify.

A planned migration to S7-1500 and TIA Portal can provide:

• Improved diagnostics and fault finding

• Current software and hardware platforms

• Improved maintainability

• Greater system visibility

• Easier future modifications and expansion

• A structured path away from ageing hardware

Proseq helps clients plan upgrades before ageing control equipment becomes a production risk.

We follow a structured, low-risk methodology tailored to each site:

Assessment & Planning

• Review of existing S7 hardware, software, and field I/O

• Risk assessment and upgrade pathway definition

• Obsolescence and compatibility analysis

• Migration strategy aligned with operational constraints

Software Migration

• Conversion of legacy S7 programs into TIA Portal

• Code optimisation and standardisation

• Alarm, diagnostics, and HMI integration where required

• Version control and documentation

Hardware Upgrade

• PLC, rack, and communication module upgrades

• Switchboard modifications where required

• Network and interface validation

• Compliance with current standards

Testing & Commissioning

• Offline testing and simulation

• Site commissioning and validation

• Production support during cutover

• Operator handover and documentation

Upgrading a live production system requires experience and discipline. Proseq has extensive experience delivering brownfield S7 upgrades in operational facilities where downtime must be tightly controlled.

We work closely with site teams to:

• Stage upgrades around production schedules

• Reduce commissioning windows

• Maintain safety and compliance throughout

• Provide rapid on-site and remote support

TIA Portal upgrades often form part of a broader automation environment. Proseq ensures seamless integration with:

• Existing HMIs and SCADA systems

• Field instrumentation and drives

• Safety systems (where applicable)

• Plant networks and remote access infrastructure

Following upgrade completion, Proseq provides:

• Ongoing technical support

• Preventative maintenance

• System backups and version management

• Upgrade documentation and asset registers

This ensures your upgraded system remains reliable, supported, and easy to maintain.

• Proven experience with Siemens S7 platforms

• Strong process engineering and automation capability

• Structured, low-risk upgrade methodology

• Practical experience in live industrial environments

• Clear communication and documentation

Proseq partners with clients to deliver safe, reliable, and future-ready automation systems.