Moranbah North Mine: ConMon SCADA Integration
The Challenge
Moranbah North Mine’s coal handling and preparation plant (CHPP) needed to integrate condition monitoring data from ConMon equipment into their existing Citect SCADA system. The site required seamless data flow from multiple IMx16 condition monitoring devices across the raw coal auxiliary stacking conveyor (CV002) into their centralised control environment, with comprehensive testing and validation to ensure reliable operations.
Our Approach
Deftec’s PCS engineering team designed and delivered a complete ConMon-to-Citect integration framework at Anglo American’s Moranbah North, mapping condition monitoring data from SKF equipment sensors across motor, gearbox, pulley, and speed monitoring points into the Citect SCADA platform. The work encompassed detailed tag configuration, Modbus register mapping, PLC integration via RedLion gateways, and full system testing both off-site and on-site at the Goonyella Road facility. Our engineers prepared comprehensive variable libraries, variable trends, and graphics templates to give operations full visibility of equipment health across the CHPP.
The Outcome
The ConMon integration delivered a unified data environment where operators could monitor critical rotating equipment condition — motor bearing temperatures, gearbox vibration, and drive pulley performance — directly within their SCADA interface. This integration eliminated data silos and enabled predictive maintenance decision-making across the raw coal handling process.
Technologies and Capabilities
- SCADA systems (Citect)
- PLC programming and integration
- Condition monitoring device integration (SKF ConMon, IMx16)
- Modbus protocol mapping
- Industrial IoT (IIoT) data aggregation
- RedLion gateway configuration
- Field instrumentation networking (10.61.192.x IP ranges)
- SCADA variable configuration, trending, and graphics
- On-site commissioning and testing
- Mining and materials handling applications