Lifecycle Management and Technology Modernization of a Legacy Control System

Abstract

This article shows a practical modernization of a legacy blender control system in a regulated pharmaceutical setting. The project replaced an Allen-Bradley SLC-500 with a CompactLogix 5380 (Studio 5000), migrated HMI/SCADA to FactoryTalk View SE on Windows Server 2022, and reused field wiring via 1492 conversion kits to limit disruption. A risk-based computer System Validation (IQ/OQ, PQ as applicable) confirmed functional equivalence, data integrity (ALCOA+), and core cybersecurity controls. SCADA and historian paths were rebound, backups were validated, and Quality authorized Return-to-Service within the planned window. Compared with complete replacement, the approach reduced capital cost, downtime, and retraining while improving supportability. The work documents method, results, and limits (e.g., targeted manual refactoring and legacy drive diagnostics) and offers a practical template for similar upgrades seeking GMP compliance, lifecycle support, and readiness for ISA-95/Industry 4.0 integration. Keywords ⎯ CompactLogix, Industry 4.0, LCM, PLC Retrofit, SLC 500, Upgrading Legacy System.