Following its privatization in 1991, the Bristol Port Company has grown into one of the most productive ports in Europe, handling a wide range of shipping, distribution, and bulk cargo operations.
Since 2005, the port has relied on TBA's CommTrac bulk terminal operating system. TBA’s involvement goes beyond software; the company has also been instrumental in developing and modernizing automation and control systems across the port’s various bulk handling and storage facilities.
At the turn of the millennium, coal was a cornerstone of Bristol Port’s business. In 2003, bulk coal alone accounted for nearly 40% of total tonnage handled by the port. Alongside coal, the port processed a significant volume of liquid bulk products (such as petroleum, aviation fuel, and chemicals) and maintained a steady stream of vehicle imports. However, over the next two decades, a rapid decline in UK coal imports forced a rethink.
Initially, the port explored biomass as a replacement commodity. However, the plans for large-scale biomass facilities (first a 150-megawatt plant at Portbury, then a 100-megawatt counterpart at Avonmouth) were ultimately abandoned. With this, the port faced a clear imperative to diversify its bulk import portfolio to maintain its commercial viability.
Back in the early 2000s, the port’s infrastructure was primarily designed around coal. Ships would dock at Portbury (1) and discharge their cargo using two CSUs, continuous ship unloaders (2). Conveyors transported the coal to a stockyard (3), where it was managed using stacker-reclaimer machinery (4). The dock also supported an adjacent animal feed storage facility.
TBA’s involvement in system modernization began in 2018 with an upgrade to the SCADA and PLC systems at the animal feed store. This was followed by a similar modernization project at the grain terminal in 2020. When coal imports ceased in 2015, the CSUs were replaced by grab cranes, which are more flexible and suited to a broader range of materials.
At the same time, a new opportunity was emerging. Etex, a global leader in plasterboard manufacturing, established a production facility adjacent to the former coal yard. In 2019, the company announced plans for a second, more advanced facility. This development presented a new logistics challenge: how to efficiently import and deliver gypsum from ship to both Etex facilities on-site.
To support this, the port’s conveyor network required significant modification. A new transfer tower, known as T1A, was constructed to divert gypsum to the existing plant. The remaining conveyor lines were extended and reconfigured to connect to a second transfer tower, TS2, which would feed the new production site. The system was designed to transfer material at a rate of up to 3,000 tonnes per hour.
TBA was tasked with modernising the control systems to support the new operational needs. The project required replacing aging equipment that had been in place since the 1990s. In the central control room, old PLC and SCADA systems were removed and repositioned, consolidating control of bulk operations into one location. Within the substations, legacy remote I/O units were replaced with new Siemens equipment. Complex relay-based interfacing systems were dismantled and replaced with clean, direct wiring to the new PLC I/O, with all logic rebuilt within the new codebase. Outdated enunciator lamp panels were replaced by modern HMI alarm displays, offering improved diagnostics and operational transparency.
The modernization effort had several key objectives. The first was to replace end-of-life equipment. This involved the complete overhaul of PLCs, remote I/O units, transformers, power supplies, and wiring. While the original control panel housings were retained, they were entirely stripped and refitted with pre-assembled backplates and new wiring. The second goal was to introduce new functionality, including the ability to manage gypsum as a bulk import, and to significantly enhance reliability and fault diagnostics through updated SCADA interfaces. All systems were also brought under a formal service-level agreement, enabling ongoing remote support and proactive maintenance.
One of the most critical aspects of the project was minimising operational disruption. While the new systems were being installed, existing bulk import operations—including those for animal feed and grain—had to remain functional. This required meticulous planning and close coordination with port operations staff, as well as with mechanical, civil, and electrical contractors.
The project centered on the replacement of two main PLCs that had been operational since around 1994. These systems were deeply integrated into the grain and animal feed facilities, meaning that their removal had to be carefully timed to avoid cascading disruptions.
The new control system comprised roughly 700 input and output signals. Ensuring all were properly mapped was a major undertaking, requiring an extraordinary level of attention to detail. Prior to the two-week installation window granted by the port, TBA conducted several site visits and worked closely with the port’s engineering and electrical teams. Fortunately, the documentation provided by Bristol Port was both detailed and up to date, offering confidence that each system replacement would be accurate.
Extensive offsite testing further mitigated risk. New CPUs were mounted, wired, and FAT-tested in advance, then linked to the SCADA system to simulate live operations. When the installation window opened, a five-person TBA team worked around the clock. Engineers were paired up to complete switchroom installations, while a fifth team member focused on resolving any real-time issues that arose. This agile deployment model helped ensure that no critical deadlines were missed.
The project also included the installation of a new fibre network, significantly enhancing diagnostics and overall system reliability. Thanks to the strong collaboration between TBA and Bristol Port staff, including project managers, engineers, and electricians, the team was able to execute the project on schedule and without compromising ongoing port operations.
The modernized automation systems now provide Bristol Port with a flexible, reliable infrastructure capable of supporting a wider variety of bulk materials. The new TCP/IP-based fibre network offers faster communication, better diagnostics, and easier integration with current and future systems. The centralized SCADA system enables efficient monitoring and real-time response, while the streamlined PLC infrastructure reduces maintenance overhead and improves system stability.
Perhaps most importantly, the project has allowed Bristol Port to pivot successfully from its historic reliance on coal. Today, the port’s revenue streams are more diverse than ever. As illustrated in recent trade data, the former dominance of coal has been replaced by a broader portfolio of bulk imports. This transformation has helped ensure the port’s continued commercial success in a rapidly changing marketplace.
This project underscores the importance of adaptability in the face of shifting market forces. For Bristol Port, modern automation wasn’t just a technical upgrade—it was a business imperative. Through close collaboration, careful planning, and a clear understanding of operational constraints, TBA Group helped deliver a future-ready control system that supports the port’s evolving strategic needs.
The result is a highly resilient infrastructure, capable of handling current demands while leaving ample room for future growth. The success of this project demonstrates how strong communication, robust technical expertise, and shared goals between client and contractor can deliver complex upgrades with minimal operational impact.
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