November 2025System Integration & Control Systems Design
The Sicomp Control System Upgrade focused on modernising a 1985 power generation control system with more than 3 000 I/O points. The plant faced increasing system failures and risk to operational continuity, making a cost-effective upgrade essential.
Project Outcome
By analysing failure patterns and targeting only critical components, the team extended system life while improving reliability. A new SCADA and HMI were implemented, providing intuitive control and diagnostics without disrupting live operations.
Biggest Challenge and Our Solution
Three main challenges shaped the project:
1. Legacy failures — The 1985 system was increasingly unreliable.
2. High cost of full replacement — Over 3 000 I/O points made a complete overhaul impractical.
3. Integration complexity — Modernising while maintaining continuity required precise mapping between old and new systems.
The solution included:
• Analysing failure patterns to prioritise replacements
• Designing a custom interface card to bridge legacy I/O with modern control systems
• Implementing new SCADA and HMI for improved visualisation and control
• Completing all upgrades without triggering system downtime
Key Technologies and Tools Used
• Targeted I/O replacement
• Custom interface card bridging legacy and modern systems
• SCADA & HMI modernisation
One Thing We’d Do Differently
Allow for phased replacement earlier in the lifecycle to reduce future legacy-system pressures.
Unique Selling Point
“Cost-effective, zero-downtime upgrades that bridge legacy hardware with modern control systems.”
What We Offer
• Targeted Legacy System Upgrades: Cost-efficient solutions for high-I/O ageing systems
• Custom Interface Design: Bridging legacy hardware with new-generation controls
• SCADA & HMI Modernisation: Intuitive visual control and diagnostics
• Zero-Downtime Implementation: All changes made while maintaining live operations
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