Grosvenor Mine: MG106EP Ventilation Fan Control System

The Challenge

Grosvenor Coal Mine required a comprehensive electrical control and instrumentation system for the new MG106 ventilation shaft — a critical upcast ventilation and downcasting cooling installation. The project demanded integration of multiple systems including a kiosk substation, fan motor control centre (MCC), bulk air-cooling (BAC) units, gas detection, and knife gate valve automation, all operating under strict mining safety standards and coordinated protection schemes.

Our Approach

Deftec designed and engineered a complete control architecture centred on CompactLogix PLC programming with Allen-Bradley 1756-series I/O modules, Ethernet communications, and integrated SCADA interfacing. The system architecture included dual digital input modules (32-point), digital output control for fan and knife gate contactors, multiple analog input channels for RTD and gas sensor data, and robust safety interlocking via protective relays (VIP410 network protection) and flame detection systems. We developed detailed electrical schematics covering incoming power distribution, PLC I/O mapping, communications topology, and field panel terminations — delivering over 25 coordinated engineering drawings. Factory Acceptance Testing protocols were established to validate processor operation, module configuration, Ethernet communications, and system health monitoring across all I/O points.

The Outcome

The control system successfully integrated ventilation fan startup, knife gate automation, BAC unit coordination, and gas safety monitoring into a single networked platform accessible via HMI and SCADA. The installation met ASNZS3800 electrical standards and ANZEx intrinsic safety requirements for underground coal mining, with arc-flash analysis confirming operator safety levels. The system provides real-time monitoring of fan VSD status, earth leakage conditions, pressure relief, and emergency shutdown across both local pendant and remote SCADA control modes.

Technologies and Capabilities

• PLC & Controls: CompactLogix 1756-L72/B processor, dual Ethernet modules (1756-EN2T), redundant I/O architecture
• I/O Modules: 1756-IB32 digital inputs (x2), 1756-OB32 digital outputs, 1756-IF16 analog inputs (x2), RTD sensing modules
• Power & Protection: 11kV/415V 2MVA transformer, Masterpact NW25H1 circuit breakers, Micrologic 5.0A relays, VIP410 network protection, Ampcontrol earth leakage monitoring
• Safety Systems: Flame detection (F-Guard units), gas guard controller, dual emergency stop circuits with safety relays, arc-flash mitigation
• Communications: Cisco IE 3300 Ethernet switch, CITECT SCADA/HMI integration, M2M Ethernet for remote monitoring
• Field Instrumentation: Temperature sensing (RTD inputs), pressure monitoring, gas detection analog signals, limit switches, VSD (variable speed drive) status monitoring
• Standards Compliance: ASNZS3800, ANZEx intrinsic safety, Factory Acceptance Testing protocols