Project Background
Client: BHP
Date: December 2022 – February 2025
Location: Pilbara Region, Western Australia
GTE was engaged by BHP to upgrade the potable water extraction, treatment, storage, and distribution SCADA system for all of their sites in the Pilbara region. The project aimed to modernise non-standardised and outdated SCADA systems and replace End-Of-Life (EOL) equipment to ensure long-term operational reliability and sustainability.
Challenges
The project faced several challenges related to the non-standardisation and lack of integration of water assets. Additionally, outdated SCADA software and EOL equipment were no longer supported by manufacturers, creating significant risks for long-term operations. The fixed plant non-process infrastructure (NPI) water assets required extensive data manipulation to meet specific requirements. These complexities needed to be resolved to achieve an efficient, modern water management system.
Approach and Solution
Advanced Technological Integration
GTE’s approach involved replacing outdated equipment and aligning all assets with the client’s technology strategy. We redesigned the water network to create a single logical network, implemented redundancy where possible to minimise single points of failure, and upgraded or replaced EOL PLC hardware. Additionally, we re-platformed client VMs and enhanced wireless infrastructure to support a unified NPI SCADA system.
Validation and Testing
We conducted thorough testing at GTE’s Perth OT Test Lab facility, including bench testing, configuration of new equipment, Layer 2 to Layer 3 migration strategy testing, and end-to-end integration. These measures ensured the system was reliable and met all performance metrics.
Innovative Engineering
Leveraging our extensive experience with the client’s systems, processes, and standards, GTE utilised knowledge gained from the Definition Phase Study (DPS) to mitigate project risks. We installed new network hardware and migrated from a Layer 2 to a Layer 3 network, ensuring futureproofing of the plant. Our strategic partnerships with Cisco and Schneider, along with our trusted OT Test Lab facility in Perth, were integral to the project’s success.
Results and Impact
GTE successfully upgraded the Layer 2 network to a Layer 3 architecture, future-proofing the plant and ensuring long-term operational reliability.
Operational Efficiency
GTE significantly enhanced operational efficiency by upgrading network hardware and migrating from a Layer 2 to a Layer 3 architecture, ensuring the plant’s long-term reliability. Involving key personnel from the DPS phase streamlined the execution process, reduced project risks, and facilitated a seamless transition. The use of GTE’s Perth-based OT Test Lab facility enabled thorough validation of power supply, network switches, and SCADA integration prior to on-site implementation.
Technological Integration and Reliability
Strategic partnerships with Cisco and Schneider allowed GTE to optimise the technological integration, standardising network configurations, upgrading EOL PLC hardware, and eliminating single points of failure. By simulating the client’s site network in GTE’s lab, potential issues were identified and resolved ahead of deployment. This approach not only improved system reliability but also ensured that the solution aligned with the client’s long-term technology strategy.
Conclusion
We conducted thorough testing at GTE’s OT Test Lab facility, including bench testing, configuration of new equipment, Layer 2 to Layer 3 migration strategy testing, and end-to-end integration. These measures ensured the system was reliable and met all performance metrics.
By standardising network configurations and upgrading EOL PLC hardware, GTE ensured enhanced system reliability and aligned with the client’s future technology strategy.
