Training is a crucial but often overlooked aspect of control system migrations. A well-planned training strategy ensures that operators, maintainers, and engineers can effectively manage and optimize the new system. Rather than being treated as an afterthought, training should be integrated into the project from the outset to facilitate a smooth transition, reduce risks, and maximize efficiency.

In part five of our control system migrations series, we explore the primary considerations for training during a system migration, addressing the different needs of various roles, the significance of simulation, location strategies, and optimal timing.

Operators vs. Maintainers

Operators transitioning to a new control system will face numerous changes, even if their previous system was relatively modern. The new system may introduce different human-machine interface (HMI) graphics, alarm handling, and security protocols, all of which require thorough training. They will also need to familiarize themselves with updated navigation structures, logging in/out procedures, and the enhanced capabilities of the new system.

Maintenance personnel, whether in instrumentation, electrical, or general maintenance, must understand the core changes in the control system, including remote I/O systems, ethernet-based field devices, and new diagnostic tools. The potential shift from traditional fuses to electronic fusing and overload protection further necessitates comprehensive training.

Engineers responsible for long-term maintenance and system modifications will require in-depth training on new programming languages, control system architecture, and system backup procedures. If the migration involves a transition from Ladder Logic to Function Block Diagram (FBD) or Sequential Function Chart (SFC) programming, engineers must gain proficiency in these new methods to effectively manage system changes.

IT teams also play an essential role in modern control systems. They must be trained in virtualized servers, cybersecurity protocols, and data historian integration. Given the increasing interconnectivity between control and business networks, IT professionals must be prepared for more sophisticated cybersecurity requirements and system failover procedures.

Balancing Hardware and Software Training

Training strategies should distinguish between hardware and software learning. Maintenance personnel often require hands-on experience mostly, with hardware components, such as controllers, networking equipment, and sensors, to handle troubleshooting and repairs effectively, but some software familiarity training is also valuable for troubleshooting purposes. On the other hand, engineers and IT staff will need to focus primarily on software training covering system configuration, programming, and optimization, but also with enough hardware training to support hardware specification decisions as well as possible implications to operations.

Ensuring that the right personnel receive the appropriate training based on their roles is vital for long-term system sustainability. Investing in role-specific training ensures that employees can operate and maintain the new system effectively from day one.

The Role of Simulation in Training

While simulation systems tend to be a significant investment, they are especially beneficial for large organizations or multi-site migration programs. Some vendors may offer simulation systems at reduced prices as an incentive to select their platform, making it a worthwhile consideration for long-term training strategies. Lower cost, although likely less realistic, simulation is also possible through the use of a desktop or laptop computer setup with a copy of the new system’s engineering and operating environments, connected to a simulated PLC.

On-Site vs. Vendor’s Location Training

Timing: When to Train Each Group

Additionally, IT teams should undergo cybersecurity and virtualization training before deployment to prepare for system integration and data security measures.

The Takeaway | Control System Migrations Training

Training should be planned early to accommodate costs and scheduling. Different roles require distinct training approaches, including hands-on hardware experience, software proficiency, and cybersecurity readiness. Although simulation-based training offers high-value learning opportunities, organizations must weigh its costs and benefits. Training location choices should balance convenience with effectiveness, and the timing of training should align with project phases to maximize retention. The cost of some training may be capitalized, depending on trainee roles and an organization’s interpretation of Generally Accepted Accounting Principles.

By investing in a structured and well-timed training approach, organizations can ensure a successful transition, improved efficiency, and long-term system reliability.