project Specifics
Rapid PLC5-to-ControlLogix migration for critical GTC operations
BSL needed to replace ageing Allen-Bradley PLC5 systems approaching end-of-life, with spares no longer available. Our Team delivered a targeted migration of the Gas Treatment Centres (GTCs) to the ControlLogix platform, prioritising safety, reliability and a tightly constrained changeover window. We completed feasibility, detailed design and conversion of legacy programs, then commissioned on site.
Valued at $88,000, the upgrade removed obsolescence risk and restored maintainable, standardised control – safer, supportable and ready for future improvements.
About the Gas Treatment Centre (GTC)
The GTCs are process-critical assets within the aluminium smelter, extracting and treating potline off-gases to capture particulates and fluorides. Reliable control and interlocks are essential to protect equipment, maintain environmental compliance and keep production running in a harsh, 24/7 operating environment.
What We Delivered
Services:
- Feasibility study & report
- Electrical design & layouts
- PLC & SCADA programming (PLC5 ladder conversion to ControlLogix standard)
- I/O remapping to ensure SCADA compatibility
- Commissioning
Delivery Method:
- Electrical engineering consultant
Outcome
The migration eliminated obsolescence risk, standardised the control environment and ensured full SCADA compatibility. Changeover was completed with minimal disruption, improving reliability and maintainability of the GTCs. Stakeholders gained confidence in long-term supportability and a clear path for ongoing optimisation.
A Welcon Project
This project was completed by our Welcon Team.
Since September 2024, Welcon Technologies has become part of SGA in a strategic move that leverages the strengths of both companies.
Welcon’s Team
