Scada/PLC Upgrade – Crown Melbourne

Specialised was responsible for the design, documentation, and delivery of a comprehensive SCADA and PLC upgrade across Crown’s complex, specifically serving the tri-generation plant, which comprises six 1.1 MW gas-fired generators. This project was crucial as the existing system, 18 years old, was outdated and no longer supported, with many parts rendered redundant.

Key tasks involved the installation of a new duplicated backbone Ethernet, spanning 2km to connect all existing and new PLCs, as well as deploying new Master and Standby Master PLCs. The project required a staged cut-over of 39 PLCs throughout the complex, the installation of new SCADA, and reprogramming of the load shed table, with the entire upgrade spread over 2.5 years to ensure meticulous planning and testing.

A significant challenge was managing and coordinating “Single Feeder Failures,” which entailed simulating power failures while the generators were either idle or operational. Additional difficulties included conducting staged cut-overs within a 24/7 facility, negotiating with relevant authorities for simulated shutdowns, and rigorous weekly testing of each PLC between 3 am and 5 am for an entire year.

This high-risk, high-profile project was essential for maintaining operational integrity within the organisation.