OT SYSTEM INTEGRATION FOR MINERAL FACILITY/
PROJECT SUMMARY
Tier16 was engaged to lead the end-to-end OT integration for a newly acquired operating salt and gypsum facility, following the transfer of ownership from a previous operator.
The acquisition included complex legacy control systems, IT/OT infrastructure, operational data sources, third-party vendor dependencies, and workforce knowledge gaps.
Tier16 played a critical role in ensuring operational continuity while modernising systems to support future growth and innovation.
CLIENT CHALLENGE
Following the acquisition, the client faced a high-risk and time-critical technology transition across an operating salt and gypsum facility.
The previous owner removed all intellectual property, servers, and computing infrastructure, leaving only system backups and limited documentation.
The existing OT environment relied on legacy hardware and control systems that had to be upgraded while the plant was shut down during the handover phase. Any extended downtime would directly impact restarting production across multiple process areas. Critical SCADA systems had to be fully rebuilt from back-ups and PLCs upgraded using existing applications.
What was originally planned as a multi-day planned outage carried significant operational risk, requiring precise execution to minimise disruption.
TIER 16 SOLUTION
Tier16 was engaged as the client’s representative and Lead Systems Integrator, responsible for the design, integration, optimisation, commissioning, and ongoing support of all site-wide OT systems.
The team developed a comprehensive rebuild, integration, and handover strategy encompassing enterprise architecture, cybersecurity, operational readiness, change management, and long-term system maintenance.
A key focus of the project was the rebuild, migration, and upgrade of legacy SCADA onto modern hardware and software platforms. All SCADA infrastructure was fully reconstructed using existing applications, while all existing PLC software was simulated to ensure SCADA functionality prior to site installation, including client FAT.
All hardwiring was shipped and installed on site ahead of the cutover date. At handover, the entire system was cut over within a tightly controlled four-hour window.
Through extensive off-site testing, rigorous QA processes, and detailed execution planning, Tier16 delivered a rapid, low-risk transition within a short planned outage. Despite limited access to legacy system knowledge, the team demonstrated strong technical depth, attention to detail, and agile problem-solving, delivering a fully operational system with zero outstanding issues.
The project scope included:
Conduct a workshop with client to determine requirements
A site visit to finalise OT/IT requirements
Compile, review and complete request for information and audit check sheet from existing owner to explore PCS environment
OT & IT Cyber security review
Create enterprise architecture to show final state for operations
Develop scope of works document and associated costs estimate to implement architecture roadmap
Review OT System dependencies from IT
Management of technology packages
IT infrastructure switch-over methodology
IT operational readiness post day zero
OT & IT ongoing system maintenance strategy
Replication of the SCADA, Historian and PLC change and management backup software.
Procure software licensing
TECHNOLOGIES USED
Schneider Electric PLCs (M340, M580)
AVEVA Plant SCADA (Citect)
Aveva Historian
Octo plant (change management)
PROJECT OUTCOMES & IMPACT
Tier16 delivered a fast, reliable, and disruption-free transition, safeguarding production while enabling system modernisation.
Zero downtime transition: All critical systems were rebuilt, upgraded, and commissioned within a tightly controlled four-hour switchover window, with no loss of production.
Rapid delivery: Full system restoration and commissioning were completed in just two to three days, far exceeding client expectations.
Legacy to modern migration: Successfully migrated legacy control systems to the latest hardware and software platforms, improving reliability, supportability, and future scalability.
Operational continuity and knowledge transfer: Ensured seamless handover and restored operational confidence despite the removal of original IP and infrastructure by the previous owner.
Agile problem solving: Overcame limited documentation and SME access through deep product knowledge, rigorous testing, and on-site adaptability.
BOM data transfer: Enabled reliable delivery of wave data to the Bureau of Meteorology by implementing a custom automated data transfer solution. This improved the accuracy and reliability of coastal weather predictions while ensuring consistent data availability from marine environment.
CLIENT TESTIMONIAL /
The team designed and implemented the new system perfectly and what was originally planned to take 2 days to changeout required hardware and configure the Virtual Machines was done in 8 hours. Each individual production area lost no more than 2 hours for each upgrade. The team were very knowledgeable and helpful in explaining the functionality of the new system and any live commissioning faults were resolved quickly. There is a great variety of skills across the team and they are able to utilise each other’s specialities to achieve any outcome. The post installation remote support was fantastic and is ongoing to this day, the quality has not dropped in any way and if anything has improved as we expand with our new systems. Andrew T.