SCADA / PLC Upgrade - Crown Melbourne | Specialised Project Management

SCADA / PLC Upgrade – Crown Melbourne

Project: SCADA / PLC Upgrade – Crown Melbourne.

Value: $2.5 M.

Role: Client Representative, Design Manager and Project Manager . Responsible for design, documentation and delivery of SCADA and PLC upgrade complex wide.

Summary

The project involved the upgrade of the SCADA and PLC upgrade serving Crowns tri-generation plant (6 x 1.1 Mw Gas fired Gensets). The system was 18 years old and was no longer supported with parts now redundant. The SCADA controls all load shedding during power failure and both HV and LV reticulation throughout the site. Works included;

Installation of new duplicated backbone Ethernet, 2km in length to link all existing and new PLC’s;
New Master and Standby Master PLC;
Staged cut-over of 39 PLC’s throughout the complex;
New SCADA and re-programming of load shed table;
Project staged over 2.5 years with planned testing.
Managing and co-ordinating “Single Feeder Failures” which involves the simulation of power failure on the site whilst the gen-sets are idle (not running) and hot (running).

Challenges

Staged cut-overs and works taking place in 24 / 7 facility;
Simulated power failures on site to test the new system – High Risk;
Negotiation with relevant authorities for simulated shutdowns;
Rigorous individual testing of each of the 39 PLC’s between 3am – 5am weekly for 12 months;
High risk, high profile project within the organisation.