All vessels need a safe, reliable, and easy-to-use control system for manoeuvring. However, after years of operation, the elements of propulsion control systems will deteriorate, and spare parts can become scarce or obsolete. This can lead to unplanned maintenance, higher operational costs, and off hire.
In response to these challenges, Wärtsilä offers propulsion control system upgrades, including cabinet-based solutions that replace control hardware while retaining existing cabinets and wiring where possible, supported by a lifecycle roadmap that aims to guarantee a minimum lifecycle of 15 years.
A cabinet based solution propulsion control system upgrade is an upgrade that includes replacement of the core controller and other control hardware while existing operator panels and wiring are retained where possible.
Why it matters:
How it works:
Where it applies:
Propulsion control systems are increasingly affected by faster development cycles in electronics, resulting in shorter component lifetimes. These lifecycles can be significantly shorter than the operational life of the vessel, creating a growing gap between system age and component availability.
As systems age, maintaining reliability becomes more challenging. Spare parts will become scarce, and repairs can take longer or become less predictable. This increases the risk of unplanned downtime and can disrupt vessel operations.
Planning upgrades in advance allow operators to manage these risks in a controlled manner, rather than reacting under operational pressure when failures occur.
A timely upgrade maintains operational continuity and removes the uncertainty that comes with ageing, unsupported systems. You replace risk with a known outcome – modern hardware, continued support, and a clear lifecycle ahead.
Cabinet-based solutions make this practical. By retaining existing operator panels and wiring where possible, the upgrade scope stays controlled and disruption to your vessel's setup is minimised. You modernise the core system without replacing the entire installation – cost-effectively, and quickly.
The result: you plan the upgrade on your terms, rather than reacting under operational pressure when something fails.
“A major concern for shipowners, especially in these days of rapid technological development, is obsolescence. Wärtsilä is ensuring better lifecycle of hardware and software by guaranteeing 15 years of component availability. After that, the company can provide an updated PCS solution for the existing equipment.
Wärtsilä propulsion control system upgrades are based on a lifecycle approach that ensures continued support and access to modern technology. During the early lifecycle phase, replacement parts are maintained, but as systems age, upgrade solutions are introduced.
A cabinet-based upgrade replaces the core control hardware such as PLC components, inside the existing cabinet. This allows the system to be modernized while keeping the original functionality of the installation, including operator panels and cabling, where possible.
Upgrade solutions are available for different propulsion applications, enabling compatibility with existing equipment while introducing updated, supported control technology.
Suitable for:
Relevant solutions include:
Wärtsilä delivers cabinet based propulsion control upgrades as part of a structured lifecycle approach. Upgrade kits are made available as systems reach later lifecycle phases and component availability begins to decline.
Cabinet-based upgrades are designed for practical implementation – the existing operator panels and wiring are retained where possible, limiting the scope and keeping integration straightforward. Support is provided throughout, covering compatibility, functionality, and continued operability.
In addition to control hardware upgrades, solutions such as Wärtsilä EcoControl can be added during retrofitting, enabling fuel efficiency improvements alongside system modernisation.
See how updating propulsion control systems with modern technology can deliver operational benefits, including improved efficiency and performance.
Example of propulsion system modernisation
This case shows how updating propulsion control systems with modern technology can improve operational performance and efficiency in practice.
Cabinet-based upgrade in practice
This video demonstrates how control hardware is replaced within the existing cabinet, while retaining key infrastructure such as wiring and cabinet structure.
“We couldn’t believe that we could save 800 litres per 24 hours while keeping the same speed. We didn’t go slower or faster, we kept at 9 knots. So we have the same power output on the water, but with 800 litres less fuel. My boss didn’t believe it.
Solution
Controllable Pitch Propeller (CPP) control system upgrades
What it is
Upgrade solutions for CPP control systems across their lifecycle
How it benefits you
Ensures reliable main propulsion control, supports full lifecycle management, and enables upgrades aligned with modern control system standards
Solution
Thruster control system upgrades (tunnel and steerable)
What it is
Control system upgrades for transverse and steerable thrusters
How it benefits you
Supports safe and predictable vessel manoeuvring, maintains reliable positioning, and enables upgrades with modern functionality
Solution
Waterjet control upgrades
What it is
Upgrade solutions ranging from cabinet-based upgrades to full system replacement
How it benefits you
Offers flexibility to match the upgrade scope to your system condition, ensuring continued operation as systems age
What it is
Smart control system that optimises propeller pitch and engine load
How it benefits you
Improves fuel efficiency and operational performance, provides cruise control functionality, and increases visibility of actual fuel consumption
Planning your propulsion control system upgrade early helps you stay in control of reliability, maintenance, and operational risk. With cabinet-based solutions, you can modernise your system in a practical and controlled way.
