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Anglo American Mining June 2021

Grosvenor Mine: MG105 Kiosk Substation Control System

SCADA PLC High Voltage Switchboards

The Challenge

Anglo American’s Grosvenor Mine required a modernised control system for the MG105 shaft kiosk substation as part of their bulk air cooling equipment relocation project. The system needed to integrate multiple protection devices---including a VIP410 network protection relay, QUINT DC-UPS, knife gate variable speed drive, and circuit breakers---while maintaining reliable communications across a Cisco industrial network.

Our Approach

Deftec designed and programmed a comprehensive control solution centred on an Allen-Bradley CompactLogix L33ER PLC, configured with 60 digital inputs, 22 digital outputs, and 11 analogue inputs to monitor the entire substation. We developed a full functional specification, programmed PLC logic to manage interlock sequences and device communications, and configured network integration through a Red Lion protocol converter to interface the VIP410 relay via Modbus. The system also integrated the QUINT UPS for critical load management and prepared the knife gate VSD interface for future commissioning. Our work included factory acceptance testing (FAT) at Major Electrical’s Mackay facility, with comprehensive test documentation covering over 90 I/O points and operational validation of all interlocks and control sequences.

The Outcome

The MG105 kiosk substation went live with a fully integrated, tested control architecture capable of managing complex protection and switching logic in a safety-critical mining environment. The modular approach---separating PLC code, network configuration, and HMI commissioning---ensured flexibility for future upgrades and maintained clear hand-over documentation for Grosvenor’s operational teams.

Technologies and Capabilities

  • Allen-Bradley CompactLogix PLC programming (L33ER controller)
  • SCADA and industrial networking (Cisco IE3000 switch configuration)
  • Protocol integration (Modbus, EtherNet/IP)
  • Protection relay interfacing (Red Lion DA30D converter, VIP410 network protection relay)
  • Uninterruptible power supply management (QUINT4 DC-UPS with EtherNet/IP)
  • Variable speed drive control (knife gate VSD integration)
  • Factory acceptance testing and commissioning documentation
  • Functional specification development for mining applications
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