PLC modernization replaces or upgrades the programmable logic controllers that manage industrial equipment. In an operating plant, the scope also includes the connected devices, software and operator interfaces. Planning starts with an accurate picture of the existing system and a clear definition of the functions the upgraded system must perform.

Rockwell Automation’s 2026 manufacturing study found that 59% of respondents actively use smart manufacturing technologies. Its modernization guidance also describes migration options for legacy control platforms. For plant owners, these developments bring new capabilities and existing equipment support into the same planning discussion.

Document the system before selecting the replacement

An equipment inventory identifies the controllers and input/output devices, along with the networks and interfaces that connect them. Current drawings and program records help the engineering team understand how the system is arranged. Discussions with operations and maintenance add context about how it is used and where support issues arise.

Functional descriptions are equally useful. They explain what the process must do, including the relationships between equipment and the operator actions involved. The upgrade can then be evaluated against defined operating requirements, with proposed changes identified explicitly instead of being mixed into a general hardware replacement.

Evaluate the migration path

A control system may be upgraded in stages or during a coordinated shutdown, depending on the application. Compatibility between retained and replacement equipment affects that choice. So do the available outage window and the work required to connect the upgraded controls to the rest of the plant.

Testing belongs in this planning stage. The project needs defined acceptance criteria and an agreed division between checks that can occur before installation and those that require the installed system. The team can also establish how discrepancies will be documented and resolved before production resumes.

Include operations in the handoff

The completed project includes more than installed hardware. Updated diagrams and software records support future troubleshooting, while training helps operators and maintenance personnel work with the revised system. Startup responsibilities and documentation requirements need to be part of the original scope so they receive time and ownership in the project plan.

R.T. Patterson Company provides automation and instrumentation engineering, including control system design, programming and field startup support. Contact RTP to discuss the existing equipment, operating requirements and migration options involved in your plant’s next controls project.

Installing a new piece of industrial equipment is rarely as simple as finding an open electrical connection and switching it on.

Large motors, process equipment, furnaces, material-handling systems and other industrial loads become part of an electrical network that may already support decades of equipment and facility expansions.

Before significant loads are added, engineers need to understand how the existing power system will respond.

That is where power system studies come in.

What is a power system study?

A power system study is an engineering analysis used to understand how an electrical system behaves under different operating or fault conditions.

Depending on the project, engineers may evaluate electrical load, available fault current, equipment ratings, protective-device coordination, voltage conditions or arc-flash considerations.

These are different analyses with different purposes, but they share a common goal: understanding the electrical system as a system rather than evaluating a single piece of equipment in isolation.

Eaton describes power-system studies as a way to understand the current state of an electrical system and develop recommendations related to reliability, equipment and safety. (Eaton)

Why can one equipment addition matter?

Electrical systems are interconnected.

Adding a significant motor or process load can change demand on transformers and distribution equipment. Changing transformers or utility service conditions can affect available fault current. Protective devices need to respond appropriately if a fault occurs.

That means equipment that appears completely adequate based on normal operating current may still need to be evaluated against other electrical conditions.

The more an industrial plant changes over time, the more important an accurate picture of the complete electrical system becomes.

What do engineers look at?

One of the first pieces of information is often the electrical one-line diagram, which shows major system components and how they are connected.

Engineers can use system information to model different conditions and answer practical questions.

Can the system serve the proposed load? Are equipment ratings appropriate? Will protective devices operate in the intended sequence? Have previous facility modifications changed system conditions?

The answers help project teams understand whether the new equipment can be integrated as planned or whether additional electrical modifications should be considered.

Why revisit studies in existing facilities?

Industrial electrical systems do not remain static.

New production lines are added. Transformers are replaced. Motor sizes change. Generators or other power sources may be introduced. Utility conditions can change.

A study completed for the facility years ago describes the system that existed at that time.

When meaningful electrical changes occur, revisiting the model helps ensure engineering decisions are based on current conditions rather than assumptions inherited from an earlier version of the plant.

Planning before installation

Power system studies are most useful when they inform decisions early enough to matter.

Discovering an electrical constraint before equipment is purchased or installation begins gives project teams more options than discovering it during startup.

That makes the study part of project planning, not simply a document created after the design is complete.

R.T. Patterson Company provides electrical engineering services that include power distribution, substation design and power-system studies for industrial environments. (LinkedIn)

Frequently Asked Questions

What types of power system studies are commonly performed?
Common studies include load-flow, short-circuit, protective-device coordination and arc-flash analyses. The appropriate studies depend on the electrical system and project.

When should an industrial facility update a power system study?
A review may be appropriate when significant equipment, transformers, electrical distribution or operating conditions change enough to affect the assumptions used in previous analyses.

Investment in U.S. steelmaking continues to create opportunities to modernize both new and existing production facilities.

In April 2026, U.S. Steel announced a $1.9 billion direct reduced iron facility at Big River Steel Works in Arkansas, where the expanded operation includes four electric arc furnaces. The company positioned the investment as part of a broader effort to improve efficiency and strengthen its next-generation steelmaking capabilities. 

Modernization is occurring within existing mills as well.

In June, Tenova announced an electric arc furnace revamp at Tenaris’ Koppel steel mill in Pennsylvania, part of more than $90 million in planned investment across the company’s Pennsylvania operations. The project includes technology designed to improve furnace cooling-water monitoring and process stability. 

These projects illustrate an important reality of modern steelmaking: upgrading the furnace itself is only one part of the engineering challenge.

An EAF Project Extends Throughout the Melt Shop

An electric arc furnace interacts with numerous surrounding systems.

A furnace replacement or capacity increase can affect foundations and structural steel, electrical distribution, cooling-water systems, material handling, alloy systems, ductwork, emissions-control equipment and access for operations and maintenance.

Brownfield installations add another challenge: fitting new equipment and systems into an active production environment.

That requires careful coordination between disciplines before installation begins.

Electrical requirements must match new equipment loads. Structural systems must accommodate equipment and operational forces. Cooling-water capacity and distribution must support process requirements. Material movement must integrate into the existing shop. Constructability and outage sequencing must be considered throughout design rather than after engineering is complete.

Engineering Around Production Requirements

R.T. Patterson Company has extensive engineering experience in the steel industry, including blast furnaces, BOF shops, electric arc furnaces, rolling facilities and associated industrial systems. Its multidisciplinary capabilities include structural, electrical, piping, automation, HVAC, foundations and material handling. 

That experience can be seen in RTP’s work supporting an EAF replacement and melt-shop modernization project for CMC Steel Texas.

The project included installation of a larger electric arc furnace during a 47-day outage, along with foundation modifications, electrical-distribution upgrades, water-cooled ductwork, alloy-system additions and consolidation of three existing cooling systems into a new cooling-water system capable of supplying approximately 32,000 GPM. 

The project demonstrates why steel modernization requires more than equipment specification alone.

Modernizing the Entire System

As steel producers invest in productivity, reliability and new technologies, engineering teams have to consider how every supporting system interacts with the production process.

A successful EAF modernization is ultimately an exercise in integration: equipment, utilities, structures, electrical infrastructure, material flow, construction sequencing and operations all have to work together.

For owners evaluating furnace replacements, capacity improvements or broader melt-shop modernization, early multidisciplinary engineering can expose constraints before those constraints reach the construction phase.

With decades of heavy-industrial and steel-industry experience, R.T. Patterson Company provides the integrated engineering required to move complex modernization projects from concept through execution.

Thirty years is more than a milestone. It’s a testament to the relationships built, the challenges overcome, and the lasting impact one person can have on a company and an industry.

As Jim Jackson celebrates 30 years with R.T. Patterson Co., we took the opportunity to reflect on his career, the mentors who helped shape his journey, and one of the accomplishments he is most proud of.

The Power of Mentorship

When asked who has had the greatest influence on his career, Jim didn’t point to a single project or achievement. Instead, he reflected on the people who invested in his success.

“The thing that stands out the most for me would have to be that I had some of the best mentors in the industry who helped me along the way. Not only several individuals at RTP, but also a vast group of individuals on the client and contractor sides who decided to make the extra effort to help me along the way. If it wasn’t for them, I wouldn’t be where I am today, and I am greatly appreciative of all of them.”

His response speaks to the collaborative culture that has long been a part of R.T. Patterson Co. and the importance of sharing knowledge across teams, clients, and industry partners.

A Career Highlight

Over three decades, Jim has contributed to countless projects, but one stands out above the rest.

“I’ve had many moments throughout my career that made me take pause, but the one that sticks out most was being presented with the Engineering Society of Western Pennsylvania (ESWP) 2013 Industrial Project of the Year Award for the U.S. Steel ‘C’ Coke Oven Battery Project. It was a six-year project where I managed the detailed installation engineering, from the initial planning and budgeting phases through installation and commissioning support.”

The award recognized not only the complexity of the project but also the dedication, technical expertise, and leadership required to bring it to completion.

Looking Ahead

Jim’s 30-year career reflects the values that have defined R.T. Patterson Co. for generations: technical excellence, continuous learning, strong relationships, and a commitment to helping others succeed.

We’re proud to celebrate this incredible milestone and grateful for the leadership, experience, and mentorship Jim has shared throughout his career.

Congratulations, Jim, on 30 years with R.T. Patterson Co. Here’s to your remarkable career and the legacy you continue to build.

Jim Jackson
Project Manager
R.T. Patterson Co.
Pittsburgh, PA

Piping is easy to overlook because much of its work happens quietly. Yet a piping system can affect production, energy use, equipment reliability, maintenance access and worker safety throughout the life of an industrial facility. 

Those effects become especially important in brownfield projects, where a new line or equipment connection must work within an operating plant rather than a clear, open site. 

Routing is only the beginning 

A workable route must account for pressure, temperature, flow, thermal expansion, vibration, support locations, equipment nozzle loads and applicable design codes. It must also leave room for valves, instruments, insulation, drainage, fabrication, installation and future maintenance. 

A route that looks efficient on a drawing may create excessive stress, block an access path or place a component where it cannot be safely operated. Piping design therefore requires constant coordination with process, mechanical, structural, civil, electrical and operations teams. 

Brownfield design starts with field conditions 

Existing facilities often include congested pipe racks, undocumented modifications, active equipment and limited outage windows. Record drawings are valuable, but they are not a substitute for confirming what is actually in the field. 

Field verification helps the team identify clashes, elevations, connection points, support conditions and constructability concerns before fabrication. It also provides context that calculations alone cannot: how operators move through the area, where maintenance equipment must reach and which systems must remain online during installation. 

Material and code choices shape long-term performance 

Material selection depends on the service, operating conditions and failure mechanisms the system may face. Carbon steel, stainless steel, titanium, Hastelloy, lined systems, fiberglass-reinforced materials, HDPE, PP, PVC and CPVC each bring different strengths and limitations. 

Code requirements matter as well. Our piping and mechanical engineers perform stress analysis for systems governed by standards including ASME B31.1, B31.3, B31.8 and B31.9. The applicable code sets the framework, but engineering judgment is still needed to address actual loads, support behavior, equipment limits and operating experience. 

Design for the people who will operate it 

Good piping design considers what happens after startup. Can a valve be reached? Can a component be removed without dismantling unrelated systems? Are low points drainable and high points vented? Can insulation be installed and repaired? Is there space for inspection and future tie-ins? 

These details may appear small during design, but they shape maintenance time, outage planning and the likelihood of field modifications later. 

For brownfield industrial work, successful piping design is not simply a system that fits. It is a system that performs under real operating conditions, can be built safely and remains practical to inspect and maintain for years to come. 

R.T. Patterson Company was proud to join Allied Resources Group for the annual Professional Engineer Recognition Dinner, held June 19, 2026, at the Union League of Philadelphia.

The event brought together Professional Engineers, Engineers in Training, leadership, and guests from across ARG’s family of companies to celebrate professional achievement and continued growth within the engineering industry.

R.T. Patterson was represented by 4 Professional Engineers across structural, electrical, mechanical, and civil engineering disciplines. The recognized PEs included Brandon Daugherty, P.E. (Structural), Russell Keefe, P.E. (Electrical), Anthony Scotto, P.E. (Mechanical), and Penny Stump, P.E. (Civil).

The company also recognized two attending Engineers in Training: Chris Cheetham, an Electrical Engineering Specialist, and Carlos Leiva, a Structural Engineer Specialist, both based in Pittsburgh.

The evening included networking, leadership remarks, recognition of newly licensed Professional Engineers and Engineers in Training, and a continuing education session presented by Zenaida Otero Gephardt, Ph.D., P.E. Her session, “Powering Tomorrow: Innovative Engineering for Next-Generation Energy Infrastructure,” focused on emerging technologies, modern energy systems, and the importance of interdisciplinary collaboration in shaping the future of infrastructure.

For R.T. Patterson, participation in the event reflects a shared commitment to engineering excellence, mentorship, and professional development. With a long history of delivering engineering solutions for heavy industrial, manufacturing, chemical, utility, and related markets, R.T. Patterson understands the value of strong technical leadership.

The Professional Engineer Recognition Dinner gives teams across ARG the opportunity to pause and recognize the people behind the work. It celebrates not only licensure and technical achievement, but also the dedication, accountability, and professionalism that engineers bring to clients and projects every day.

As part of Allied Resources Group, R.T. Patterson is proud to support a culture where engineers are valued, emerging talent is encouraged, and professional growth remains a priority.

Read the full event recap and view photos from the evening on Allied Resources Group’s website: https://argroupllc.com/news/allied-resources-group-hosts-annual-professional-engineer-recognition-dinner-at-the-union-league-of-philadelphia/

By Mark Deenik, BSE 
General Manager, R.T. Patterson Company, Merrillville, IN 

When I joined RTP as a Mechanical Engineer in 2005, I didn’t expect my career to evolve into leadership roles. Over time, I moved from Mechanical Department Manager to Project Manager, Assistant General Manager, and now General Manager of our Merrillville office. One thing has remained constant throughout that journey: the importance of strong relationships. 

Early in my career, my focus was on detailed drawing production and individual tasks. As my role expanded, I shifted toward managing workloads—and ultimately people—which I’ve come to value most. Whether working with employees, clients, or partners, building cohesive, trusting relationships is essential to both team performance and project success. 

Here are a few key lessons I’ve learned along the way: 

• Foster a collaborative environment – Encourage open communication, teamwork, and mutual trust and respect. 
• Support professional development and growth – Invest in training, certifications, workshops, and conferences. I’m particularly interested in emerging tools like artificial intelligence. While AI isn’t replacing engineering jobs anytime soon, it can streamline design, data analysis, and evaluations. Like any tool, its value depends on proper understanding and thoughtful use. 
• Listen and communicate effectively – Strong interpersonal skills matter at every level. Take time to understand client needs and focus on solutions—everyone benefits from clear, purposeful communication. 
• Stay flexible – Reading the room and adapting your approach helps ensure your message lands as intended. Leadership requires guiding the overall direction while remaining agile as priorities shift, projects change, or teams evolve—without losing sight of long-term goals. 

Advice for Emerging Leaders 

For those stepping into leadership roles, seek out someone who’s already successful in the position you aspire to and build a relationship with them. Learn from both their successes and setbacks. At the same time, recognize that others may be looking to you for guidance—be approachable, open, and willing to share. 

Engineering is as much about people as it is about projects. Strong relationships, clear communication, and adaptability allow teams to thrive, offices to grow, and clients to succeed. When those elements align, great work follows naturally.

Electric utilities depend on transformers to maintain the flow of power from generation plants to homes and businesses. These critical components ensure electricity is delivered safely, efficiently, and without interruption. Replacing and upgrading transformers is a complex engineering challenge that requires precision, planning, and multidisciplinary expertise. 

Ensuring Reliability Across Power Generation, Transmission, and Distribution 

Transformer replacements are essential for preventing unplanned outages and maintaining grid stability. Engineers must carefully plan each project, considering electrical loads, structural foundations, civil modifications, and safety measures. Every decision, from foundation design to electrical layout, directly impacts system reliability and the safety of personnel performing the work. 

Case Studies in Transformer Replacement Projects 

At the Harrison Power Station, the Unit #3 700 MVA GSU transformer replacement involved relocating the existing transformer and installing its replacement on a new foundation. Engineers prepared electrical drawings, designed foundation modifications, and created structural steel plans. The project also included new lightning arrester towers to enhance safety. By integrating electrical, civil, and structural expertise, the project was completed smoothly, minimizing operational disruption. 

Similarly, at the Albright Station, RTP replaced the 150 MVA Unit #3 GSU transformer and made the necessary electrical, civil, and structural modifications. Engineers updated relaying schemes, installed new foundations and access platforms, and prepared detailed drawings to ensure proper relocation and integration of the existing transformer as a station spare. STAAD software was used to evaluate bridges for transformer transport, highlighting the attention to detail required for high-voltage projects. 

The R. Paul Smith Station Unit #4 Auxiliary Transformer Replacement demonstrated the importance of precise engineering in supporting critical infrastructure. The project involved revising relay panel layouts, updating DC schematics, and installing dissolved hydrogen and water monitors for enhanced system monitoring. Each step ensured the transformer operated safely and reliably within the larger power network. 

The Impact of Transformer Replacements on Industrial Operations 

Transformer upgrades are about more than replacing equipment. They sustain the backbone of the power grid. Proper planning, structural and electrical evaluation, and integration with existing systems reduce the risk of outages and improve overall efficiency. Each project contributes to long-term operational resilience and supports the reliable delivery of power to communities and industries. 

Building Safe and Resilient Power Systems 

Transformer replacement projects illustrate how careful engineering can prevent failures, optimize performance, and ensure safety. By combining electrical, civil, and structural expertise, these projects demonstrate that reliable power delivery is not accidental; it is engineered. Through detailed planning, precise calculations, and rigorous attention to detail, transformer replacements keep power flowing safely and efficiently. 

Industrial facilities depend on engineering solutions that perform safely and efficiently every day. When systems fail or underperform, the consequences can include unplanned downtime, safety risks, and lost production. Reliable engineering is not about completing a project quickly—it is about delivering solutions that function consistently, meet operational and regulatory requirements, and support long-term facility performance. 

Why Trusted Engineering Matters 

Engineering is valuable only when it produces predictable and durable outcomes. Facilities require systems that maintain performance under operational stress, changes in demand, and evolving safety standards. Trusted engineering ensures that modifications, upgrades, and maintenance provide both immediate results and lasting reliability. 

Investing in reliable engineering reduces operational risk, protects personnel, and strengthens confidence in facility operations. It allows operators to plan for the future knowing that critical systems will continue to meet performance expectations. 

Core Principles of Reliable Engineering 

Reliable engineering is built on practical expertise, thoughtful planning, and long-term thinking. Essential components include: 

• Practical Design Solutions – Implementing engineering decisions that function effectively in real-world operating conditions. Designs account for actual facility workflows, environmental conditions, and operational constraints. 
• Safety and Compliance – Ensuring all systems meet regulatory standards and internal operational requirements. Compliance is integrated into every step of the engineering process, from planning to execution. 
• Innovation with Purpose – Introducing improvements that enhance performance without creating unnecessary complexity or operational risk. Every change has a clear benefit to efficiency, reliability, or safety. 
• Cost-Effectiveness – Balancing technical excellence with responsible budgeting. Reliable engineering delivers lasting value without unnecessary expenditure. 

Focusing on these principles ensures that engineering work not only meets immediate needs but provides a foundation for sustained operational success. 

Building Long-Term Partnerships 

Reliable engineering extends beyond individual projects. It requires ongoing collaboration with clients to understand operational objectives, anticipate challenges, and provide consistent support. Long-term partnerships allow engineering teams to: 

• Deliver predictable, repeatable results across multiple sites and projects. 
• Anticipate operational challenges and implement proactive solutions. 
• Align engineering improvements with broader strategic goals and operational priorities. 

By fostering strong client relationships, engineering teams reduce risk, improve system reliability, and provide confidence that solutions will continue to perform over time. 

Real-World Example: CMC Steel Texas Electric Arc Furnace Project 

The Electric Arc Furnace installation and cooling system upgrade at CMC Steel Texas demonstrates the impact of reliable, client-focused engineering. During a 47-day outage, a new, larger furnace was installed while an existing unit was replaced. Engineering support included foundation work, duct replacements, electrical upgrades, and system modifications that maintained alignment with production requirements. 

Additionally, three separate cooling water systems were consolidated into a single 32,000 GPM service system designed to accommodate future expansion. By integrating practical design, operational planning, and safety considerations, the project was completed efficiently, safely, and with long-term durability in mind. The result is a system capable of supporting operations for years to come while minimizing the risk of downtime or failure. 

The Impact of Consistent Engineering 

Facilities benefit when engineering is reliable, practical, and client-focused. Consistency in design, implementation, and support builds operational resilience, strengthens safety, and ensures that critical systems continue to perform over time. Trusted engineering allows operators to plan with confidence, knowing that upgrades and modifications will deliver durable results, protect personnel, and support long-term operational goals. 

In today’s digital economy, data centers don’t just store information, they power entire industries. With the rise of AI, cloud platforms, and real-time data processing, these facilities are under growing pressure to operate at massive scale with zero tolerance for downtime. 

But the resilience of a data center begins long before the servers go online. It starts with the infrastructure built to support it, from the substation and steel to the cooling systems and control networks. 

At R.T. Patterson Company (RTP), we bring nearly 70 years of experience engineering utility-grade infrastructure for sectors where operational continuity is non-negotiable. That same discipline now helps data center developers build for performance, scalability, and future demand. 

From Industrial Centers to Server Farms: Engineering for High-Stakes Environments 

Data centers demand the same level of system reliability and lifecycle durability as the heavy industrial facilities we've supported for decades. Our legacy in manufacturing, power generation, and petrochemicals gives us deep insight into: 

• Specialized mechanical systems 
• Integrated electrical and control systems designed for uptime and efficiency 
• Coordinated infrastructure layouts that simplify future expansion and ongoing maintenance 

We understand how to engineer systems that operate 24/7, because we’ve done it for industries that never stop. 

Supporting the Infrastructure That Supports the Cloud 

Our work doesn’t stop at engineering drawings. We collaborate with developers, utilities, EPCs, and contractors to help engineer the physical systems that support data center operations. Our infrastructure services include: 

• Electrical Engineering: Medium- and low-voltage distribution, substations, fault studies, and coordination 
• Mechanical Systems: HVAC systems for power and control rooms, cooling support piping, and process utilities 
• Automation & Controls: Instrumentation and control logic that ties systems together and provides real-time visibility 

These are the foundational elements that allow data centers to scale confidently and operate reliably from day one. 

Built for Today. Engineered for Tomorrow. 

Every data center is evolving. Power demand is rising. Technologies are shifting. Uptime expectations are growing stricter. 

Our approach to design and engineering accounts for that uncertainty, delivering infrastructure that supports what’s needed today and prepares for what’s next. That means: 

• Maintainability built into the layout, not added later 
• Code compliance embedded from the start, including seismic and wind loads and electrical reliability benchmarks 
• Integrated commissioning support that ensures systems work together as designed 

Whether the project is greenfield or retrofit, RTP brings consistency, quality, and foresight to every phase. 

Infrastructure Experience That Moves With the Market 

With engineering hubs in Pittsburgh, Merrillville, and Evansville, RTP offers both regional insight and national reach. Our clients rely on us not just for technical execution, but for our ability to work side-by-side with EPCs, developers, and owners to move projects forward efficiently. 

Our infrastructure experience spans: 

• Power generation and utilities 
• Petrochemical and heavy manufacturing 
• Industrial automation and process systems 
• High-reliability, high-demand environments where failure is not an option 

This is where we’ve built our name. And these are the challenges we’re built to solve. 

Conclusion: A Trusted Engineering Partner for Mission-Critical Infrastructure 

Building a data center means more than deploying servers and cables—it means delivering the infrastructure that will carry tomorrow’s technologies. That infrastructure must be durable, flexible, and engineered for long-term performance. 

R.T. Patterson brings the systems-level thinking and field-proven engineering that critical operations depend on. We’re not just designing for uptime, we’re designing for what’s next.