PCS 7 / WinCC Migration – Safely Upgrade to the Latest Version
As a certified Siemens Solution Partner, Bilfinger is your experienced specialist for migrating PCS 7 control systems to current versions.
We understand: An outdated process control system jeopardizes plant availability and safety. That's why our pre-migration service offers you a decisive advantage – we verify the compatibility of your application before you commission the full migration. This gives you complete planning certainty, a clear understanding of the effort involved, and minimizes your risk.
The actual migration is then carried out with minimal operational downtime, aligned with your production cycles.
What is a PCS 7 / WinCC Migration?
A PCS 7 migration refers to the systematic upgrade of a Siemens SIMATIC PCS 7 process control system to a newer PCS 7 version. This involves not only the software, but often also hardware, firmware, operating systems, and network infrastructure. The goal is to ensure long-term plant availability and compliance with safety standards.
We migrate all PCS 7 versions from V6.0 to V10.0 – including all service packs. Whether you want to upgrade from V8 to V10 or from V8.2 to V9.1.
All key information about PCS 7 upgrades at a glance – available as a PDF download.
Our Services for Your PCS 7 Migration
From hardware analysis to long-term lifecycle management – Bilfinger supports every PCS 7 migration with a modular service portfolio.
We assess all automation components: Which parts are still available, and which need to be replaced? Firmware updates ensure that the controllers meet current security requirements. The result: Hardware supply is secured, and spare parts costs are reduced.
Outdated operating systems are a security risk – both for PCS 7 and for WinCC-based systems – in accordance with Siemens release lists. Upon request, we migrate systems to virtual environments. This saves space, reduces maintenance effort, and increases availability.
After the PCS 7 migration, the system should be protected against attacks. We install approved patches, segment networks, and prepare the system for audits – such as NIS2 requirements. Secure remote access can also be set up.
A migration is not a one-time project. With our lifecycle management, documentation stays up to date, Profibus analyses prevent communication issues, and regular reviews against BSI security alerts ensure ongoing protection. This keeps the plant up to date even after the migration is complete.
In addition to PCS 7 migration, Bilfinger also supports WinCC migration as well as updating TIA Portal projects to current versions. The existing application is analyzed, compatibility is verified, and the system is safely brought up to date – including adjustments to hardware, operating systems, and network infrastructure. The result: Plants outside the PCS 7 environment also benefit from a secure control system migration with minimal operational downtime.
Bilfinger supports the migration of all common PCS 7 versions to current systems:
- PCS 7 V6.0 (incl. SP1, SP2, SP3)
- PCS 7 V6.1 (incl. SP1, SP2, SP3)
- PCS 7 V7.0 (incl. SP1, SP2, SP3)
- PCS 7 V7.1 (incl. SP1, SP2, SP3, SP4)
- PCS 7 V8.0 (incl. SP1, SP2)
- PCS 7 V8.1 (incl. SP1)
- PCS 7 V8.2
- PCS 7 V9.0 (incl. SP1, SP2, SP3)
- PCS 7 V9.1 (incl. SP1, SP2)
- PCS 7 V10.0 (incl. SP1)
PCS 7 Pre-Migration – Planning Certainty Before Commissioning
The pre-migration is a key component of a successful PCS 7 migration. Before the actual control system migration begins, the existing application is migrated to the target version in a test environment. This allows compatibility issues to be identified early – before budget and schedule are finalized.
Benefits of PCS 7 Pre-Migration:
Early identification of compatibility issues
Realistic effort estimation for the PCS 7 upgrade
No unpleasant surprises during the actual migration
Transparent decision-making basis before full commissioning
Reduced project risk for operators and service providers
At Bilfinger, the pre-migration is an integral part of the migration process and can also be commissioned as a standalone service – ideal for operators who want to modernize their process control system but first need a thorough analysis.
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How Your PCS 7 Migration Works
Initial Consultation – We analyze your current system landscape and assess how you can modernize your PCS 7.
Pre-Migration – Verification of application compatibility on the target version – essential for every successful control system migration.
Tailored Proposal – Transparent, budget-adapted, with a realistic schedule for your PCS 7 upgrade.
Implementation – Execution with minimal operational downtime – your process control system remains productive.
Lifecycle Management – After the migration, we provide continuous support: keeping plant documentation up to date, maintaining control cabinets (e.g., battery replacement, filter cleaning), and performing Profibus analyses.
Frequently Asked Questions About PCS 7 Migration
Hardware components typically receive 10–15 years of manufacturer support, but process plants often operate for 20–25 years. Servers can become difficult to replace after just 5 years. A timely migration prevents unplanned downtime.
In October 2025, Windows 10 will lose its regular security update support. At the same time, decentralized peripheral devices of the ET 200M family will reach the product discontinuation milestone. This means: double pressure to act for operators of PCS 7 systems. A PCS 7 upgrade should therefore be planned promptly.
During the pre-migration, we verify the compatibility of your application on the target version – before you commission the complete PCS 7 migration. This allows us to identify potential problems early, giving you planning certainty for your control system migration.
That depends on the system size and complexity. After the pre-migration, we can provide you with a realistic schedule for your PCS 7 upgrade. Typical projects where customers modernize their process control system take between a few weeks and several months.
Yes, our concept for control system migration is designed for minimal operational downtime. We align the PCS 7 migration with your production cycles.
Yes, in addition to PCS 7 migration, we also support WinCC migration to current versions. We can also handle other manufacturer systems as part of a control system migration.
