Anglo American Aquila: Compressor Station Control Integration

The Challenge

Anglo American’s Aquila Underground Mine needed to integrate four Atlas Copco compressors, two driers, and a main switchboard into a unified monitoring and control system. The challenge was consolidating data from multiple intelligent devices and field sensors — including pressure transducers, differential pressure sensors, and flowmeters — while providing remote operation of the main incomer breaker, all feeding into the site’s SCADA infrastructure.

Our Approach

Deftec designed and programmed an Allen Bradley CompactLogix PLC to serve as the data aggregation and control hub for the compressor station. The system bridges the Atlas Copco equipment (which communicates via CAN protocol through an ES6 master controller) with traditional switchboard instrumentation using a Red Lion protocol converter and Modbus communications. Our PLC code architecture follows ISA95 control system standards, organised into functional groups for the main incomer, each compressor, driers, and transformer supply. We handled complete integration of non-Atlas equipment — air receiver pressure transducers, differential pressure sensors across pre- and post-filters, and compressed air flow measurement — mapping all inputs and outputs to a comprehensive database accessible by SCADA. The system includes remote open/close capability for the main incomer breaker with validity checking and fault alarm generation if communications fail.

The Outcome

The completed system provides Aquila with real-time visibility of compressor running status, load/unload cycles, warnings, and shutdowns across all four units, plus dryer health monitoring and switchboard fault states. Remote operators can manage the main incomer from anywhere on the network with confidence in data integrity. The modular code design and documented tag structure made handover to the site SCADA team straightforward, reducing commissioning risk and supporting future maintenance.

Technologies and Capabilities

• PLC Programming: Allen Bradley CompactLogix (RSLogix, IEC 61131-3)
• Communications: Modbus RTU, CAN protocol translation, Red Lion DA30D protocol converter
• Field Instrumentation: Pressure transducers, differential pressure sensors, flowmeters, earth leakage detection (ELD)
• Switchboard Integration: Circuit breaker position feedback, multifunction power meter comms, UPS status monitoring
• Control & Monitoring: Remote breaker operation, alarm generation (critical/warning/log levels), trend data logging
• Design Standards: ISA95 control architecture, site-standard tag naming and code organisation