- 15 min
When Sibanye-Stillwater embarked on a project to modernise its Rustenburg pack operations, the goal was clear: to replace ageing legacy systems with a more intelligent, more secure, and highly scalable solution. Partnering with Concera, the team embraced Ignition and delivered a cutting-edge SCADA application that’s transforming operations.
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From Vision to Reality: Introducing the Team
At the heart of the project were passionate experts committed to innovation.
Jacques Venter, Concera:
“We’re thrilled to showcase what we’ve built for Sibanye. It’s been an exciting journey over the past few months.”
Sibusiso Masego, Unit Manager, Control & Instrumentation, Sibanye-Stillwater:
“We recently embarked on a journey with Ignition, replacing legacy systems in our Rustenburg operations. It’s a significant step into the future.”
Johan Louw, Technical Specialist, Sibanye-Stillwater:
“I see this as a journey into the future. We are on the ship, and we’re not staying behind.”
Their collaboration gained global recognition this year at the Ignition Community Conference (ICC), hosted by Inductive Automation. Concera and Sibanye-Stillwater won a Firebrand Award, selected as one of the best technical stories submitted worldwide, in recognition of the innovation and impact of their application.
Tackling Challenges Head-On
The project had ambitious requirements, particularly in the area of Abnormal Situation Management (ASM). The system needed to:
- Be highly user-friendly for operators and technical staff
- Highlight abnormal situations clearly through intuitive visuals
- Integrate seamlessly with stringent cybersecurity standards
- Scale efficiently across multiple sites
Johan Louw on security:
“Even with tightened cybersecurity measures, Ignition allowed us to take our web interface outside the traditional boundaries. Notifications on Teams and mobility options were now possible without compromising security.”
The team also had to navigate tight timelines, completing templates, architecture, and development across three shafts and ten compressors within three months—an actual test of skill and coordination.
High-Performance ASM in Action
The result is a high-performance ASM system that transforms day-to-day operations. Operators now benefit from:
- Immediate fault visibility through a straightforward, colour-coded interface
- Remote monitoring and control, even during network outages, thanks to edge gateways
- A framework that standardises screens, alarms, and security across all sites
Sibusiso Masego:
“The user-friendliness is outstanding. Operators can now see what’s going on at a glance, and colour coding helps them take action quickly. Even remote compressors are fully managed despite network challenges.”
Smart Architecture, Seamless Scalability
The architecture employs a hub-and-spoke model, where a centralised IT hub securely connects to multiple SCADA systems, with fully redundant edge gateways deployed at remote compressor stations.
Jacques Venter:
“We leveraged the PLC standards already in place, building templates that are easy to scale and implement across new sites. This ensures continuity and efficiency.”
Johan Louw:
“The framework Concera built allows us to replicate the system at other sites with a consistent look, feel, and functionality. It’s a huge step for scalability.”
Lessons Learned & Innovations
Every project brings lessons, and this one was no exception:
- Segregating projects for ASM and PLC standards streamlined development
- Leveraging backend tag providers minimised coding and simplified operations
- Edge gateways and remote tag providers allowed seamless data integration across sites
Jacques Venter:
“If you can dream it, you can build it. The ideas that come from the Sibanye team are challenging, but Ignition makes it possible to deliver them.”
Sibusiso Masego:
“We also embedded operator training directly into the system through videos. This not only aids adoption but excites operators about using the new standard.”
The Business Impact
Sibanye-Stillwater’s Ignition deployment isn’t just a technical upgrade; it’s a business game-changer:
- Managers and engineers can view operations remotely via web services
- Decisions are informed in real-time, with alerts delivered on Teams
- Reduced need for additional licenses compared to legacy SCADA systems
- Future expansion is easier thanks to a standardised, secure framework
Johan Louw:
“The system allows us to bring critical data to decision-makers efficiently. Whether at a desk or on Teams, they can act in real-time, keeping us ahead of the curve.”
Looking Ahead
The journey doesn’t stop here. The team is now working on:
- Enhanced local security for easier, more resilient access
- Expanded web service capabilities for broader visibility
- Ongoing operator training and adoption strategies
Sibusiso Masego:
“Every day we discover new features. The combination of Ignition’s flexibility and our team’s ideas ensures continuous improvement.”
A Successful Digital Transformation
The Sibanye-Stillwater project is a textbook example of how innovation, teamwork, and the right technology platformcan transform operations. By embracing Ignition, the team not only replaced legacy systems but set a new standard for efficiency, usability, and scalability across the business.
Johan Louw:
“For those considering Ignition, it’s not just the cost, it’s the excitement it brings to developers, operators, and decision-makers alike. This is the future of smart operations.”
Concera and Sibanye-Stillwater’s Firebrand Award is a proud recognition of this success, celebrating their pioneering work.