Oaky Creek North: Tailgate CH4 Monitoring System

The Challenge

Glencore’s Oaky Creek North Coal required a robust methane monitoring system for their tailgate roadway—a critical safety application in underground mining where real-time gas detection is non-negotiable. The system needed to span a 4.5 km cable run from the sensor to the start-of-block installation, operate reliably in intrinsically safe conditions, and interface seamlessly with their existing Austdac site-wide gas management system.

Our Approach

Deftec designed and engineered a comprehensive CH4 monitoring solution centred on Ampcontrol’s Gasguard 2 detector integrated with an iMAC 2 controller. The system architecture featured a 300Wh intrinsically safe UPS to power the sensor across the extended 4.5 km run, with voltage drop calculations ensuring the Gasguard 2 display received a safe minimum of 10.2V. We manufactured a custom skid to house the UPS, iMAC controller, and terminal interface at the start of block, complete with a 4-channel digital output module for trip functionality. Engineering work included IS entity calculations, electrical schematics, control system programming, and factory acceptance testing—all supported by a comprehensive technical dossier and operator training package.

The Outcome

The completed system delivered a reliable, certified methane monitoring solution ready for deployment in one of Australia’s key coal mining operations. By May 2024, the system had progressed through manufacturing, HMI development (including a CR1000 touchscreen display to show methane as a percentage rather than raw 4-20mA readings), and final documentation, positioning Oaky Creek North with a modern, user-friendly gas safety platform integrated into their broader mine control infrastructure.

Technologies & Capabilities

• Control Systems: Ampcontrol iMAC 2 controller, Gasguard 2 CH4 detector (0–5% range)
• Power & Safety: 300Wh 12.6V intrinsically safe UPS; IS entity calculations and certification
• Signal Transmission: 4.5 km iMAC cable runs; resistance and voltage drop analysis
• I/O Modules: 4-channel DO module; DI4 local reset/bypass interface; Moxa Ethernet switch
• HMI & Integration: CR1000 4-inch touchscreen with custom methane percentage display; Dupline system interface
• Design & Engineering: Electrical schematics, skid fabrication, PLC programming, FAT, technical documentation, operator training