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PLC Replacement in oil storage depot

PLC Replacement Project – UK Oil Storage Depot

Project Overview

In 2021, our team successfully delivered a major control system upgrade at a live oil storage depot in the UK. The project involved replacing ageing and obsolete GE Fanuc PLCs with state-of-the-art Allen Bradley PLCs, all while ensuring the depot remained fully operational. This upgrade was essential to maintain the depot’s reliability, safety, and compliance with modern industry standards.

Planning and Collaboration

Given the critical nature of oil storage operations, meticulous planning and close collaboration with the client were central to the project’s success. We worked closely with site management to develop a phased approach, ensuring all works were carried out safely and with minimal disruption. Changeovers requiring system isolation were scheduled at agreed times, with clear communication to all stakeholders throughout.

Why Upgrade?

The existing GE Fanuc PLCs had become obsolete, raising concerns about the availability of spare parts and ongoing support. The new Allen Bradley PLCs provide robust technical support and enable cloud-based modifications, offering greater flexibility and efficiency. Future updates can now be carried out remotely, reducing the need for site visits and minimising downtime.

Key Project Activities

Key activities included:

  • Removing non-essential and decommissioned wiring and PLC cards to streamline the system and reduce potential failure points
  • Installing and wiring a shadow Allen Bradley PLC, allowing for thorough parallel testing before the final switchover
  • Deploying a new industrial PC for enhanced graphics and operator interface
  • Upgrading network cabling and installing new relays for improved control and monitoring
  • Conducting comprehensive system testing across key bays to ensure a seamless transition
  • Executing the final cut-over with minimal disruption to ongoing operations

Results and Impact

Thanks to careful planning and teamwork, the project was completed with less than 20 hours of total disruption to terminal throughput—well below the original estimate of 40 hours. All works were finished in under 15 days on site, demonstrating our commitment to efficiency and operational excellence.

Client Testimonial

“The GE Fanuc Rack Relocation works have now been completed. This was a critical milestone in the Plymouth PLC Upgrade project, and a stage with significant risks to the operational stability of an exceptionally stable terminal. All of these works were carried out with a total of less than 20 hours’ disruption to the throughput of the terminal, and in under 15 days on site. This is well beyond my original hopes and expectations for a task as complex and high risk as this, and the efforts of all involved need to be applauded.”

Future-Proofing UK Infrastructure

This project highlights our ability to deliver complex automation upgrades in live, high-risk environments across the UK. By investing in modern, supported technology, we help ensure the long-term reliability, safety, and efficiency of critical national infrastructure.


PLC Rack connections PLC Rack connections
PLC Rack connections PLC Rack connections
PLC Rack connections PLC Rack connections