Oaky North Coal: TC04 Condition Monitoring System

The Challenge

Oaky Creek North’s conveyor network was running with mixed, non-standardised condition monitoring equipment across critical mechanical assets. The TC04 Tripper location had no monitoring system in place, creating a blind spot in the operation’s ability to detect early-stage equipment failures before they impacted production. The client needed a standardised, integrated condition monitoring solution that could be rolled out consistently across the trunk conveyor system.

Our Approach

Deftec designed and manufactured a comprehensive TC04 Condition Monitoring Enclosure---a custom 800x600x300mm stainless steel cabinet housing dual Pruftechnik VIBGUARD IIoT modules for real-time vibration analysis and alarm handling. The system integrated 20 Hansford HS-150S accelerometers and 12 temperature sensors across critical drive pulleys and bend points, with data aggregated through Allen-Bradley Flex I/O PLC architecture, Moxa Ethernet switching, and OMNITREND Asset View software for visualisation. Deftec also supplied four satellite junction boxes positioned at walkside, non-walkside, and drive locations to extend monitoring coverage across the tripper’s mechanical train. Custom high-temperature FEP cable assemblies with 2-pin MS connectors ensured reliable signal integrity in the harsh mining environment.

The Outcome

The standardised TC04 system established a baseline for condition monitoring deployment across Oaky North’s conveyor network, enabling predictive maintenance scheduling and reducing unplanned downtime. With integrated vibration and temperature trending, the operation gained early warning capability on bearing degradation, pulley misalignment, and thermal events---translating to improved asset life and production reliability. The VIBGUARD platform’s novel alarm handling technology provided site reliability teams with actionable intelligence and a scalable framework for future installations.

Technologies and Capabilities

• Condition Monitoring and Diagnostics: Pruftechnik VIBGUARD 7.810 IIoT modules, vibration and temperature sensing networks
• PLC and Control Architecture: Allen-Bradley Flex I/O (Ethernet modules, digital I/O, analog input)
• Industrial Networking: Moxa EDS-G509T Ethernet switch, Red Lion DA30 protocol converter
• Sensor Technology: Hansford HS-150S accelerometers (100mV/g), HS-200SRT temperature transmitters
• Enclosure Design and Manufacturing: Custom stainless steel IP68-rated cabinets with sloped roof design
• High-Temperature Cabling: FEP insulation, screened assemblies rated to 150 degrees C
• Data Visualisation: OMNITREND Asset View software integration
• Installation and Commissioning: On-site deployment coordinated with mine maintenance windows, compliance with AS/NZS electrical standards