Legacy Boiler PLC Migration for an OEM
Legacy boiler PLC programs moved onto a current platform and verified through I/O testing, giving the OEM a consistent baseline for new installations.
Scope & approach
Steamtech Engineering is a boiler OEM that installs across multiple end-customer sites, and its boiler automation ran on ageing legacy PLC programs that every new installation inherited. The task was a legacy PLC migration with a goal beyond any one site: the migrated program had to become a maintainable baseline suitable for repeat deployment, not a one-off conversion. Metromotion Controls migrated the legacy code base onto current Rockwell CompactLogix and PanelView platforms, verified the migrated logic against the field through structured I/O testing, and supported commissioning from the OEM workshop through to Steamtech end-customer sites. The result is a more consistent controls baseline across new installations, which is easier for Steamtech and its customers to support.
What was delivered
- Legacy boiler programs were migrated onto current platforms and verified through I/O testing, giving Steamtech a more maintainable base for repeat OEM deployment.
- Commissioning support extended from the OEM workshop through to the Steamtech end-customer sites.
- New installations benefited from a more consistent controls baseline across the product range.
Scope items
- PLC program migration from legacy to current automation platforms
- I/O testing and on-site commissioning activities for new installations
- Ongoing engineering support to Steamtech end customers post-commissioning
Services and sectors behind this work
Industrial automation project delivery
Melbourne automation contractor capability for scoped control-system projects from design through commissioning.
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Modernise legacy PLC, SCADA, HMI and control infrastructure with staged cutover planning.
Automation commissioning, FAT, SAT and audits
Commissioning engineers, acceptance testing, loop checks, startup support and control system readiness audits across Australia.
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PLC programming, troubleshooting, commissioning and legacy migration for Melbourne production sites.
Energy and utilities monitoring
Electricity, water, gas, steam and compressed air metered on the control network and reported beside production.
Process plant automation
Process control for chemical, process and utility plants: loops, sequences, batch, boilers, steam and utilities.
DCS vs SCADA vs PLC for process plants
How to choose a control architecture for an Australian process plant, expansion or migration.
SLC 500 and PLC-5 end-of-life upgrades
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Legacy PLC migration planning
Planning an upgrade without losing production on a live Australian manufacturing site.
Building products automation
Process control, kiln and dryer stability, material handling and data for bricks, tiles and heavy clay plants.
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