Project and Industry

November 2025 System 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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