GE Upgrades Controls for Esso Australia's Longford Gas Plants

As a Trusted OEM, GE Performs Mark V to VIe Migration for Esso Australia’s Longford Gas Turbines


Esso Australia’s fleet of gas turbine digital control systems was comprised of two Mark VIe and three Mark V systems. The facility wanted to upgrade the aging Mark V controls and outdated software to a more modern system which would ensure long-term maintainability, support and performance. Longford required a cost effective upgrade option with minimal outage time. The advanced solution would need to increase reliability and include continued support to ensure critical machines maintained optimal performance and productivity.


Esso Australia selected GE for its unmatched experience in upgrading and unifying controls, and GE conducted a successful upgrade of the first of the three Mark V control system to the Mark VIe control system. GE provided a cost-effective, direct plug-n-play replacement for the legacy controls, which limited the outage duration to only two weeks.

“A big advantage and part of the outstanding success of this project was that it was delivered jointly by the GE and Esso Australia teams without any additional contractors or third-party resources, which significantly reduced total project costs,” said Gerald Mckay, Senior Electrical Technician, Esso Australia.


The Longford facility now has the latest GE controls technology with guaranteed long-term support. GE’s Mark VIe technology offers flexible distributed architecture, decreasing installation time and ongoing maintenance costs. In addition, its model-based control technology provides enhanced performance based on improved design margins that provide more flexible operation. Esso Australia recognized the value in a proven original equipment manufacturer (OEM) provider, because a successful control system retrofit extends beyond the upgrade itself. GE provides instrumental support for all sensors, controllers, actuators and fuel valves as well as the turbine. GE’s full spectrum support ensures asset health and safety as well as limited downtime.


By upgrading to the Mark VIe control system, Esso Australia received the benefits of both advanced control system technology and GE expertise, including:

  • The migration solution did not disturb Longford’s field wiring and utilized the existing controls cabinet, saving approximately two weeks of installation time. This reduced upgrade costs as well as lost production.
  • Longford increased productivity and can continue to optimize turbine performance with the solution’s advanced diagnostics and the ability to add additional software and hardware enhancements.
  • The migration of the entire fleet of digital control systems to the Mark VIe platform has allowed the Longford facility to store all critical data in a single system for greater transparency and control.

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For more information, contact:

Holly Spiers



Rachael Tucker

InkHouse, for GE