Oaky North Coal: 110kW Pump Starter Refurbishment and Control System Integration
The Challenge
Oaky North Coal’s existing PS80 pump starter switchboard needed modernisation to support a 110kW submersible pump installation at their Tieri operation. The client required not just equipment refurbishment, but a complete systems integration including soft starting capability, remote telemetry, and comprehensive control and monitoring — all built to AS/NZS mining safety standards.
Our Approach
Deftec refurbished the existing PS80 switchboard and repurposed it as a 415V, 110kW starter incorporating a soft starter unit, 250A main breaker, and earth leakage protection. We engineered the complete control architecture, including PLC programming and commissioning protocols aligned with AS/NZS 3007 and AS/NZS 3000 electrical standards. Critically, we integrated a telemetry radio system wired into the starter, enabling remote monitoring of pump performance. The project included full electrical schematics, general arrangement drawings, and a detailed commissioning dossier---essential for mining operations where documentation and traceability are non-negotiable.
The Outcome
The refurbished PS84 starter delivered a modern, compliant control solution that extended the life of existing infrastructure while adding remote monitoring capability. By bringing the system up to current mining electrical standards and integrating IIoT-ready telemetry, Oaky North gained visibility into pump operation and the ability to respond to issues before they impact production. The comprehensive commissioning documentation and C0—C6 certification framework ensures safe, reliable operation and supports the client’s compliance and maintenance schedules.
Technologies and Capabilities
- Switchboard refurbishment and repurposing (PS80 platform)
- Soft starter control (110kW, 415V, 3-phase)
- Main circuit protection (250A MCCB with earth leakage)
- PLC programming and control logic
- Telemetry radio system integration
- SCADA and HMI development
- Electrical design and arc flash analysis
- AS/NZS 3007, 3000, and 3008 compliance auditing
- Factory acceptance testing (FAT) and site commissioning
- Mining-grade equipment dossier and documentation