Grosvenor Mine: Dual 160kW PC Pump Dewatering Station Control System
The Challenge
Grosvenor Mine needed to automate a dual 160kW Progressing Cavity (PC) pumping system for dewatering the lower sections of longwall panels LW106-109. The system had to operate reliably in an underground mining environment while maintaining precise water level control across multiple boreholes — with zero tolerance for unplanned downtime that could flood critical mining zones.
Our Approach
Deftec engineered a complete PLC and SCADA control system centred on redundant level measurement and closed-loop pump speed control. We developed intelligent monitoring logic that continuously compared dual Ex ia level transducers (with automatic failover if measurement variance exceeded 5%), integrated dual variable speed drives for smooth motor acceleration, and programmed a sophisticated bypass valve arrangement to maintain stable reservoir levels during fluctuating underground feed conditions. The system was factory-tested at our Mackay facility, then commissioned on-site at Grosvenor Mine with full documentation including start-up sequencing, manual/auto operating modes, and remote monitoring via Anglo American’s SCADA network.
The Outcome
The system was successfully commissioned in August 2023, delivering automated water level control with redundancy safeguards and transportable design allowing leapfrog deployment across multiple longwall panels. Operators gained both remote visibility and manual override capability for commissioning, while the intelligent control logic eliminated the need for on-site power infrastructure underground — a key client requirement.
Technologies and Capabilities
- PLC programming and control logic (multi-mode start/stop sequencing, level-based speed ramping)
- Variable Speed Drive (VSD) configuration and integration
- Redundant sensor monitoring with automatic failover and alarm logic
- SCADA development and site integration
- Modbus RTU/TCP network configuration and device communication
- Ex ia intrinsically safe field instrumentation integration
- Factory acceptance testing and commissioning procedures
- Industrial networking (Ethernet switch configuration, IP addressing)