Rapid Control System Reverse Engineering & Rebuilds
Exka uses proprietary offline automation tools to reverse engineer and rebuild control systems across PLC and SCADA brands, reducing engineering time and cost. We reconstruct engineering datasets and missing control documentation, and deliver runnable, rewritten PLC and SCADA applications for client review and testing.
From the existing system to a working rebuild
- 1
Analysis & reverse engineering
A traceable baseline of the existing system, documentation gaps and open questions.
You review and confirm
- 2
Engineering data & documentation
A structured engineering dataset, control descriptions and supporting lists and drawings.
- 3
PLC & SCADA rewrite
Runnable new PLC and SCADA applications.
- 4
Client trial
Hands-on experience of the new system before any site work.
You return an issue list
- 5
Fixes, improvements & virtual commissioning
An updated system, test records, and a close-out record for every issue.
You accept the virtual FAT
- 6
Site implementation & handover
A maintainable system with updated documentation and engineering data.
You sign off SAT
Operate the rebuild before site work
Clients receive a runnable PLC and SCADA rebuild to operate and inspect before any site work, and confirm control behaviour, screens, alarms and diagnostics for themselves.
- Normal start and stop
- Auto / manual changeover
- Sequences
- Interlocks
- Alarm acknowledge and reset
- Equipment faults
- Communication failures
- Recovery to normal operation
- Event recording
A data foundation for digitalisation
Reliable digitalisation starts with well-defined plant data. Exka rebuilds equipment structures, tag definitions, alarms, interlocks and event-recording logic alongside the control system, giving reporting, asset management, MES and analytics platforms a consistent and traceable source of operational information.
- One asset hierarchy, naming convention and equipment model. Equipment and data can be related across systems.
- A data dictionary and explicit state definitions. Fewer misinterpretations and repeated mappings.
- Rules for start, end, cancel, reset and reason codes. Events and statistics can be traced.
Drivers and templates
exKa SRTP Driver for Ignition
Read and write published PACSystems variables by name from Ignition, without maintaining an address map.
- Emerson PACSystems RX3i
- Ignition 8.3 (8.1 coming soon)
- SRTP (GE Ethernet)
exKa UMAS Driver for Ignition
Access Modicon variables and data structures by name from Ignition, browsable straight from the PLC.
- Modicon M580, M340, Quantum, Premium
- Ignition 8.3 (8.1 coming soon)
- UMAS
exKa HMI Standard Library for Ignition Perspective
Reusable equipment models, operator screens, alarms and diagnostics for Ignition Perspective.
- Ignition 8.3 Perspective
- Siemens S7-1500 reference project
Selected case studies
Mining & ResourcesRO Plant Reverse Engineering, Rebuild and SCADA Integration
Standalone RO package reverse engineered and documented, its control logic rebuilt to the main plant standard, and the plant integrated into the main SCADA with motor-control and device visibility.
Food & ManufacturingFood Facility Control-System Recovery and Recommissioning
Engineering recovery of a temperature-controlled food facility after care-and-maintenance: project files and setpoints recovered, control behaviour checked and the facility recommissioned.
Process IndustriesProcess Plant Control-System Delivery
WA-based process plant control-system delivery from scratch using Siemens S7-1500 and Citect, from PLC template development through to commissioning and handover.
Data, virtual commissioning, new systems and support
Discuss your existing system
Tell us which PLC and SCADA you run, roughly how large the system is and what documentation exists. A first enquiry does not need project files.