A major local steelmaking client engaged our services for their steelmaking WTP upgrade, which required complete automation. In doing so, their goal was to reduce risks due to no longer relying on an old control platform and improve the consistency of slurry density sent to the de-watering plant.

Upgrading the control system would allow them to operate more efficiently as they would have fewer unplanned downtime events. In addition, it would lower maintenance costs due to having better data from the plant about its operation and consequently being able to make more informed decisions.

Our engineering and technology team worked closely with the client’s in-house engineering team to produce the detailed design.


  • Designing the new control system for the steelmaking WTP upgrade.
  • Writing the functional specification and test procedures.
  • Design of the new Programmable Logic Controller (PLC), field input/output (I/O) panels, and also Ethernet IP network.
  • Selection and supply of the PLC and instrumentation hardware.
  • PLC programming.
  • I/O mapping to the main BOS plant macro view system.
  • Testing of new Macroview water treatment plant (WTP) screens.
  • Factory acceptance testing (FAT) and commissioning.
  • Work completion occurred while the plant was fully operational, and also a 48-hour window for cutover and commissioning.

Control systems

  • PLC5 to ControlLogix migration using conversion chassis.
  • Re-use of I/O existing wiring where possible.
  • PLC5 code conversion utility and also testing.
  • New Point I/O in field termination panels via Ethernet/IP to CLX PLC.
  • Replace the old data line and also panelview with a new macro view operator client screen.
  • Use I/O mapping standards to ensure consistency of code with the existing control system.
  • Construct all new control and I/O panels, and also install them next to the current system ready for cutover.
  • Extensive testing of the system prior to both installation and cutover.


  • Replacement of legacy systems significantly reduced risk due to obsolete control hardware.
  • The plant started up without delay and had a smooth changeover of the system due to a thorough planning and testing regime.
  • Automation reduced line blockages and downtime. In addition, it also provided a more consistent slurry product to the de-watering plant.
  • The whole system was cutover, tested, and also re-commissioned within the required 48-hour window, with no issues, on budget, and also on time.

”The upgrade has meant improved consistency of the slurry density being sent to the dewatering plant.  Consistency of product is the key.”