At the South32 GEMCO Rowell Highway Power Station, reliability is non-negotiable. The facility supplies power to the local community, which means even the slightest downtime can have significant consequences. When the need arose to replace 18 obsolete Modicon PLCs with modern Siemens S7-1500 PLCs, I S Systems was tasked with delivering a seamless, compliant, and low-risk upgrade—without interrupting ongoing operations.
Upgrading critical control systems in a live power plant requires precision, deep expertise, and a strategy that prioritises continuity. The solution needed to meet modern standards while ensuring full transparency of system behaviour throughout the transition.
To achieve a smooth changeover, I S Systems implemented a staged upgrade methodology supported by ibaPDA and ibaHD-Server. These tools enabled engineers to:
This non-intrusive monitoring ensured each step was validated, allowing for absolute confidence at every stage of the upgrade.
The project delivered a modernised control system while keeping the power station fully operational. Benefits included:
● Minimal downtime across the entire upgrade process
● One-at-a-time generator transitions, with safe decommissioning and recommissioning
● Master controller upgrades performed under manual control for added safety
● Smooth return to automatic mode, with no issues post-handover
Because iba is a non-invasive diagnostic solution, the upgrade required no additional wiring or major system disruption. Even after project completion, the iba system was left in place to continue providing valuable operational insights — and four years later, it remains actively used.
This project demonstrates how combining engineering expertise with advanced monitoring technology can significantly reduce risk during complex modernisation work. For critical infrastructure like power generation, this approach ensures reliability, transparency, and confidence during major transitions.
The successful upgrade at South32 GEMCO highlights the value of thoughtful planning, staged execution, and intelligent diagnostic tools. By integrating modern PLC technology with real-time monitoring, I S Systems delivered a future-ready solution that strengthened reliability without disrupting critical operations. This case stands as a model for how essential infrastructure can be modernised safely, efficiently, and with long-term value in mind.
