The Rockwell Automation white paper outlines strategies for upgrading aging Distributed Control Systems (DCS) to modern automation platforms. Key decisions include hot vs. cold cutover, phased vs. rip-and-replace migration, vertical vs. horizontal upgrades, and replication vs. innovation. Hot cutovers and phased approaches minimize downtime and risk, while innovation yields better ROI than simple replication through improved HMIs, optimized control, and smart I/O. Effective project management—often with third-party expertise—is critical to control costs, meet schedules, and ensure smooth transitions with minimal operational disruption.

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