Legacy System Modernization Emerges as $18.5B Market Opportunity in 2025
ARC Advisory Group's latest report reveals aging industrial control systems now account for 62% of unplanned downtime globally, driving a 214% surge in retrofit investments since 2022.
Critical Data Points
• Energy waste in 15+ year-old systems: 18% average increase
• Diagnostic delay reduction: 34 hours → 8.9ms post-upgrade
• Cybersecurity incidents: 81% decrease with IEC 62443 protocols
Saudi Aramco's Predictive Maintenance Breakthrough
Through Bently Nevada's System 1® integration, the energy giant achieved:
73
$2.1M
92%
"The $18.50 ROI per dollar invested makes legacy modernization not just an engineering priority, but a financial imperative,"
— McKinsey Industrial Practice Lead, May 2025 Report
Three-Phase Retrofit Roadmap
Edge Connectivity (0-48hrs):
Deploy Asset Sentry EDGE modules with Modbus/TCP protocol bridging
Health Monitoring (Week 1):
Activate real-time diagnostics via System 1® software (98.7% accuracy)
Validation (Week 2):
Ensure ≤10ms latency and IEC 62443 compliance
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