Case Study: OneSteel Whyalla achieves safer, more reliable skip hoist control with Rockwell Automation

OneSteel Whyalla Upgrades Critical Skip Hoist Control System

OneSteel Whyalla needed to upgrade its aging skip hoist control system before a short maintenance window ended, since any shutdown of the blast furnace could mean major productivity losses. The company turned to Rockwell Automation for a locally designed, manufactured, and commissioned solution using Allen-Bradley GuardLogix systems and PanelView Plus operator interfaces, along with a safety risk assessment.

Rockwell Automation replaced obsolete controllers and interface hardware while retaining the reliable third-party power module, helping keep costs down. The new system improved visibility into production, added redundant overspeed and overwind protection, and met Safety Integrity Level 2 requirements, exceeding South Australian safety standards. The upgrade was completed within the limited shutdown window and has been operating well since commissioning.

OneSteel Whyalla

Craig Foulkes

Iron Making Electrical Engineer