Modernisation of Legacy Systems
Legacy Ship-Shore Safety Link Controller Upgrade – 19 Inch Rack-Mount System
Overview
RDS partnered with a major Northern European LPG terminal to modernise a legacy ship-shore safety link controller that had been in continuous operation for more than 20 years. The system was business-critical, forming a key part of the terminal’s safety infrastructure, and any upgrade needed to be carried out with extreme care and minimal operational disruption. Obsolescence is always a factor in all of RDS systems designs, we help extend the life of legacy systems to avoid waste and reduce long terms costs.
RDS delivered a true drop-in replacement that preserved all certified interfaces while introducing modern hardware and a significantly improved operator experience and extend system life.
Challenge & Objectives
The existing safety link controller was approaching end-of-life, creating increasing risk around long-term support, hardware availability and maintainability. However, replacing the system outright would have introduced substantial cost, downtime and re-certification requirements.
The client’s objectives were highly specific:
A direct, 100 percent compatible replacement for the existing controller
No changes to certified field wiring or mechanical interfaces
Preservation of all existing safety functionality and logic
A modern operator interface to improve usability and diagnostics
Long-term hardware and software support
Completion of the upgrade within a tightly controlled maintenance window, with no extended downtime
Design & Development
RDS engineered the solution as a true drop-in 19 inch rack-mounted replacement, using detailed 3D CAD to ensure complete mechanical and electrical compatibility with the legacy system.
All existing functionality was carefully replicated, while internally the system was upgraded to incorporate modern industrial PC hardware and a contemporary operator interface. The design approach was deliberately focused on avoiding:
System re-certification
Re-cabling or changes to field wiring
Operator retraining or procedural changes
By maintaining identical external interfaces and behaviour, the new controller could be installed seamlessly into the existing safety architecture.
Production, Installation & Commissioning
The first upgraded unit was manufactured, tested and delivered by RDS before being installed during a planned 48 hour maintenance window. The replacement achieved a full changeover with zero operational impact, allowing the terminal to resume normal operations immediately after commissioning.
Following the successful installation and commissioning of the initial unit, the customer elected to standardise the RDS platform for future upgrades across multiple European terminal sites.
Outcome & Impact
The upgrade significantly extended the operational life of a critical safety system while avoiding the cost, risk and disruption associated with a complete system replacement.
By delivering a modernised controller that integrated seamlessly with existing infrastructure, RDS enabled the client to:
Resolve obsolescence risks
Improve day-to-day usability
Maintain full safety compliance
Protect prior investment in certified systems
Customer feedback highlighted the value of the approach:
“RDS delivered a solution that not only solved our obsolescence problem but genuinely improved day-to-day operation. Upgrading a two-decade-old safety system in a single weekend is a testament to the quality of the engineering.”
Key Takeaways
Drop-in replacement for legacy safety-critical infrastructure
Full electrical and mechanical compatibility
No re-certification, re-wiring or retraining required
Rapid installation within a controlled maintenance window
Scalable platform adopted across multiple sites
RDS specialises in modernising legacy and safety-critical systems, delivering low-risk upgrades that extend system life while improving performance and usability.
