Moranbah North Coal Mine: Flygt Pump Control System

The Challenge

Anglo American’s Moranbah North operation required a reliable, multi-mode control system for critical dewatering pumps at the site. The system needed to integrate an IPD (Intelligent Protection Device) protection relay with a keypad interface module, support both manual DCB (Direct Control Box) and automatic float-based operation, and provide real-time monitoring of motor parameters including phase currents, voltages, and trip status — all while maintaining strict safety interlocks.

Our Approach

Deftec designed and delivered dual GE RX3i-based control systems (PD031 and PD032) featuring integrated SCADA architecture with industrial-grade networking. Each system comprised a GE IC695CHS007 7-slot chassis with dual CPE310-ACAT processors, dedicated input/output modules, and RS-485 Modbus communication to the IPD relay. We engineered the PLC logic to handle three distinct operating modes — auto, manual, and DCB — with mode-dependent trip logic that latches faults appropriately while allowing automatic restart on float-based recovery events only. The systems were networked via Cisco IE2000 managed switches with comprehensive VLAN segmentation, and integrated with GE QuickPanel HMI touchscreens for operator interface and data visualization. All raw IPD data (50+ Modbus registers) was mapped to PLC registers and presented on operator displays showing motor current, phase voltages, IPSI node status, and historical trip conditions.

The Outcome

Both PD031 and PD032 completed factory acceptance testing in January 2022 with all 16 digital I/O channels and analog telemetry confirmed operational. The control systems successfully demonstrated mode switching logic, fault detection across seven trip categories (including incoming MCCB status, phase rotation, machine stop, and motor undercurrent), and reliable communications under site network conditions. Operators at Moranbah North gained real-time visibility of motor health and protection relay status through the HMI, enabling faster diagnostics and reducing unplanned downtime on critical pump assets.

Technologies and Capabilities

• GE RX3i PLC platform with dual Ethernet-enabled processors
• Modbus RTU serial integration to IPD intelligent protection relays
• Multi-mode pump control logic (manual, automatic float-based, DCB)
• Fault latching and auto-reset logic conditional on operating mode
• Industrial Ethernet switching (Cisco IE2000) with VLAN routing
• GE QuickPanel HMI with real-time motor telemetry and trend display
• Comprehensive FAT test protocols and site commissioning documentation
• AS/NZS3800 and ANZEx compliance for coal mining environments