German Creek: Grasstree West Overland Conveyor Dupline Upgrade
The Challenge
Anglo American’s German Creek operation relied on an aging dupline pull key system for emergency lockout and shutdown procedures on the Grasstree West Overland Conveyor. The existing system suffered from poor reliability, creating unplanned downtime during both routine maintenance and emergency situations. The client needed a modernised, dependable control solution that met current mining safety standards while integrating seamlessly with existing infrastructure.
Our Approach
Deftec developed a comprehensive turnkey upgrade encompassing design, supply, installation, and commissioning. We redesigned the electrical architecture---replacing point-to-point dupline wiring with an RS485 communications link to the existing PLC---while conducting detailed cable analysis across the 7 kilometre conveyor run to optimise voltage drop performance. Our work included a full SIL risk assessment and functional safety audit against AS/NZS 3007:2013 and AS/NZS 4024.3610:2015, coupled with stainless steel pull key stations featuring integrated termination enclosures and prestart beacons. The delivery encompassed factory acceptance testing of all lockout assemblies, three weeks of supervised site installation with a dedicated project manager and field electricians, and one week of specialist commissioning support by a dupline systems expert.
The Outcome
The upgraded system delivered significantly improved reliability and reduced conveyor downtime during both planned shutdowns and emergency events. Comprehensive documentation---including training manuals, maintenance strategies, critical spares lists, and testing records---ensured Anglo American’s team could operate and maintain the system with confidence moving forward.
Technologies and Capabilities
- SCADA and PLC communications (RS485 integration)
- Dupline emergency shutdown systems (Austdac)
- Electrical design and cable engineering (voltage drop analysis, 7 km conductor sizing)
- Functional safety and SIL risk assessment (mining compliance)
- AS/NZS 3007:2013 and AS/NZS 4024.3610:2015 standards audit
- Industrial control panel design (stainless steel enclosures)
- Factory acceptance testing (FAT) and commissioning
- Project management and site installation supervision
- Mining-grade electrical systems for conveyor applications