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Innovative Thinking

How Premier Helps Steel Plants Modernize Legacy Systems

Aging Control Rooms and Rising Risks 

Across the United States, steel industry control rooms look frozen in time: drive cabinets from the 1980s, PLC racks running on obsolete firmware, and yellowed paper schematics. The mechanical equipment still does its job, but the automation systems behind it are decades past their intended lifecycle, with risks that grow every year. 

For maintenance leaders, that means struggling to find replacement parts. For operations directors, it means higher downtime costs and slower production recovery. 

For corporate decision-makers, it means hundreds of millions of dollars in capital at risk if a critical failure forces a full replacement. 

Premier Automation understands this reality. As the largest independent Drives Division in the U.S. and a proven legacy integration specialist, we’ve helped steel producers extend the life, reliability, and performance of their plants—without the disruption of total system replacement. 

Modernizing to Address Risks in Aging Control Systems 

To remain competitive, steel plants must upgrade their assets. An entire overhaul of equipment and systems is not the answer, as it can require years of project planning and disruptive construction. The most cost-effective and non-disruptive way to ensure a smooth transition that establishes reliability, safety, and performance is to modernize legacy systems.   

Steel plants across the country face many common challenges when operating with outdated systems – each with a proven modernization solution: 

  • Limited Process Visibility → Real-time monitoring and analytics give operators instant insight. 
  • Frequent Unplanned Downtime → Predictive maintenance and upgraded parts prevent breakdowns. 
  • Obsolete Vendor Dependence → Modern, open systems ensure support and easy parts sourcing. 
  • Poor Integration with Safety/Quality Systems → Phased upgrades link legacy assets to modern tech. 

Modernization is not as simple as replacing old parts—it’s about positioning your plant for the future. A targeted modernization program can extend the life of existing assets by multiple years. This approach creates a digital-ready foundation for future automation.    

Delivering those results requires a partner who understands both the complexity of steel plant operations and the urgency of keeping production online. 

How Premier Automation Powers Innovation in the Steel Industry 

Modernization is a strategic investment that delivers operational stability, boosts workforce efficiency, and strengthens competitive advantage, which is why it is crucial to work with a trusted partner to guide the process.    

Premier Automation has been helping the metals industry tackle challenges for decades. We bring a rare combination of deep industry experience, unmatched drive system expertise, and proven integration capabilities across the full range of automation platforms.  

In recent projects for leading steel producers, Premier has:   

  • Replaced obsolete DC drives with high-efficiency AC systems, improving uptime and reducing energy costs.   
  • Integrated low-cost, modern PLC hardware into existing networks for greater reliability and maintainability.   
  • Delivered phased upgrades to finishing lines, enabling production to continue without costly shutdowns.  

“Premier Automation is more than a solution provider. They’re an asset to anyone in the steel industry.” - Louis Covelli, Electrical Lead at U.S. Steel’s Gary Works  

These projects consistently deliver higher throughput, reduced downtime, and improved operator confidence—results that speak directly to the bottom line.   

Why Premier? 

Largest Independent Drives Division in the United States: We specialize in complex DC and AC drive upgrades, no project is too complex for our team, and we thrive on solving the toughest challenges in the industry 

  • Custom Integration Expertise: Our solutions are designed to fit into your existing spaces, saving you money, conserving space, and reducing downtime.  

  • Legacy Integration Specialists: Whether you’re running GE, Reliance, Siemens, Rockwell, ABB, Westinghouse, or custom-built systems, we know how to modernize without starting from scratch.  
  • Minimal Downtime Execution: Our phased project approach keeps your production running while upgrades are staged and installed.  
  • Single-Source Accountability: From design and commissioning to long-term support, we provide one point of contact for every stage of the project.   

If your plant relies on outdated drives, PLCs, or control systems, or you’re turning to eBay for spare parts, the time to modernize is now. Start with a no-cost modernization assessment—and see how we can extend the life, performance, and profitability of your existing assets.  

  

Driving Success in the Steel Industry: A U. S. Steel Testimonial

How Premier Automation Helped Modernize Critical Mill Operations at Gary Works

Premier Automation Announces Launch of Premier Innovation Hub with Support from the Commonwealth of Pennsylvania

 

MURRYSVILLE, PA — Premier Automation today announced the launch of the Premier Innovation Hub, a new facility in Westmoreland County that will serve as a national model for industrial automation, workforce development, and technology commercialization. The Commonwealth of Pennsylvania has committed more than $3 million in support through a combination of grants, loans, and training funds. 

Premier Automation’s Thanksgiving Basket Donation: Continuing the Tradition of Giving Back

At Premier Automation, we take pride in giving back to the community. This Thanksgiving marked the second annual basket donation drive organized by our Premier Volunteers committee, continuing our tradition of supporting local families in need.

Premier Automation Announces the Creation of Premier Labs: A Corporate Venture Studio Focused on Automation, Robotics, and AI

Monroeville, PA – October 9, 2024 – Premier Automation, a leader in engineered and automation solutions, announces Premier Labs, a corporate venture studio focused on creating companies that leverage proven automation, robotics, and artificial intelligence solutions to solve industrial challenges.

Thanksgiving Basket Donations

Posted on May 14, 2024 by Emma Stein

Premier Automation's Thanksgiving Basket Donation: Spreading Joy in Our Community

Premier Automation is committed to making a positive impact in our local community that extends far beyond innovation. Through initiatives such as the Thanksgiving basket donation drive organized by our dedicated committee, Premier Volunteers, we are honored to give back to our community and support those in need.

Premier Pro League

Posted on May 14, 2024 by Emma Stein

Premier Pro League: Camaraderie and Competition at All American Fieldhouse

Premier Automation’s Premier Pro League is the perfect mix of camaraderie and competition! This opportunity allows us to bring our team together at the All-American Fieldhouse for monthly sporting events. From dodgeball to ultimate frisbee and everything in between, our employees can unleash their competitive spirits while staying active and having fun with other Premier team members.

The Benefits of Working at Premier Automation

Premier Automation: A Unique Career Opportunity in the World of Electrical Work

Are you passionate about electrical work and looking for a fulfilling career? Premier Automation might just be the place for you! In this blog post, we'll explore the experiences and insights of five individuals - Dave, Connor, Lizzy, Keith, and Mike - who have found their calling at Premier Automation, a company that not only values its employees but also offers a wide range of career opportunities in the field of electrical work.

Learning about Industrial Networks

 

Higher level automation components such as PLC’s, Drives, and HMI’s communicate with each other through industrial networks. These allow them to pass more advanced data back and forth between them as opposed to a single true or false signal from a single wire. There are many different types of communications, types of hardware, and topologies that allow these networks to operate. The most common types of industrial networks are Ethernet IP, Profibus, and Profinet, but there are many others as well. Modbus, Ethercat, Canbus, and Controlnet are a few of the many other types that we see in applications.

Learning about Mechanical Guarding

 

For a robot to safely operate in an industrial setting, it needs appropriate guarding to protect both the operators from the equipment in the cell. It also protects the equipment from external forces that can damage it, or move devices from the taught positions they need to be in. These cells are not a barrier to keep the inside separated from the outside. Items that need worked on must enter the cell, get worked on, then exit in a safe manner to ensure operator safety, and efficiency of the process. To do this, both mechanical and electrical guarding components are designed and implemented together.