Extending the operational life of an Italian Power Station with an MCS II to MCS III Retrofit
15th October 2026 | Castlet
Sector: Power Generation
Castlet helped a major Italian power company extend the operational life of its electrostatic precipitator (ESP) with an upgrade from obsolete MCSII control equipment to a modern MCSIII system.
The retrofit project provided a practical, long-term solution for the power station, retaining the existing plant infrastructure while reducing the risk of unplanned downtime. Documentation and replacement hardware were supplied within eight weeks, with installation and commissioning completed within a one-week outage.
THE CHALLENGE
Our client provides base load power to the Italian electricity network, making reliable operation of its equipment a key priority.
The power station’s electrostatic precipitator (ESP) plays an essential role in controlling particulate emissions.
The existing MCS II control equipment for the plant’s ESPs had become obsolete, with no replacement spares available. A failure could therefore have resulted in significant unplanned downtime, potentially affecting the station’s operation.
The challenge was to modernise the control system while retaining the existing ESP infrastructure and keeping disruption to the power station to a minimum.
“Projects like this demonstrate the value of combining detailed engineering design with a practical understanding of existing plant infrastructure. By integrating the retrofit with infrastructure and completing installation within a one-week outage, we modernised the control equipment while minimising disruption and reducing the risks associated with obsolete equipment.”
Ian Fox, Industrial Sales Manager at Castlet
The Objective
Our objective was to deliver a future-ready control solution that would support the continued reliable operation of the ESP for many years to come.
The project focused on:
Completing the installation and commissioning within a limited outage period.
Our Solution
Castlet’s engineering team began by reviewing the original installation documentation, building a detailed understanding of the existing system and its interfaces with the wider plant.
Using this information, the team produced new circuit diagrams to support the MCSIII upgrade, ensuring the replacement equipment could be integrated effectively with the existing infrastructure.
The approach enabled the power station to modernise its control system without the cost, complexity and disruption associated with wholesale replacement of the ESP installation.
Careful coordination of engineering and delivery activities was essential to minimising disruption. Castlet supplied the required documentation and replacement hardware within eight weeks, with installation and commissioning subsequently completed within a one-week outage.
The Outcome
Our engineers retrofitted the obsolete MCSII control equipment with MCSIII technology, providing the power station with a modern control system designed to support the continued operation of its ESP while retaining existing plant infrastructure.
The key achievements included:
By taking a proactive approach to equipment obsolescence, the power station reduced a significant operational risk while preserving its existing infrastructure.
Looking to Modernise Obsolete ESP Control Equipment?
Ageing or unsupported control equipment can present a significant risk to the reliability of your plant.
Castlet provides engineered ESP control upgrades and retrofit solutions designed to integrate with existing infrastructure, minimise disruption and support reliable operation throughout equipment life.
Contact our team to discuss how we can help modernise your existing ESP control system.
If Castlet can help you with high tech electronic solutions fill in your details below, or call
+44 (0) 1522 876 700