Moranbah North Mine: Ventilation Shaft to Borehole Intertripping Upgrade

The Challenge

Moranbah North Mine required a modernised intertripping control system to safely manage power distribution across multiple ventilation shafts and boreholes. The existing system relied on legacy Dupline and SILBUS panels scattered across multiple sites — creating maintenance complexity and limiting operational flexibility. Anglo American needed a unified, network-based architecture that could reliably coordinate emergency shutdowns across underground power feeders while maintaining safety-critical functionality in a demanding coal mine environment.

Our Approach

Deftec designed and delivered a phased PROFINET migration strategy centred on a new master controller in the Control Room (CRO), replacing point-to-point legacy communications with industrial Ethernet. We specified Emerson PACSystems RX3i controllers and PROFINET scanners across multiple substations and ventilation locations, then systematically migrated field panels at Shafts 1, 2, and 6, and Boreholes 1, 2, 5, and 6. Each phase included hardware installation, panel modifications with digital and analog I/O modules, PROFINET network integration, and comprehensive commissioning checksheets covering hardware compliance, software validation, and safety-critical functionality. The project incorporated detailed functional block diagrams, rigorous testing protocols, and decommissioning of redundant equipment post-commissioning.

The Outcome

The upgraded system provides Moranbah North with a modern, centralised control architecture that improves reliability, reduces commissioning time, and simplifies future maintenance. By consolidating legacy infrastructure into a unified PROFINET network, Anglo American gained clearer visibility of intertrip status across all critical shafts and boreholes. The phased rollout — delivered across three phases — allowed the mine to commission and verify each stage before proceeding, minimising operational risk.

Technologies and Capabilities

• Control Systems: Emerson PACSystems RX3i PLC controllers, PROFINET master/scanner architecture
• Industrial Networking: PROFINET IRT, fibre-optic connectivity, Ethernet infrastructure
• I/O & Sensing: 32-point digital input modules, 16-point digital output modules, 8-point analog modules, pressure transmitters (Rosemount 3051)
• Legacy Integration: DUPLINE, SILBUS, and Modbus protocol translation; structured decommissioning
• Field Panels: Custom-built control and monitoring panels with selector switches, push buttons, LED indication lights, and emergency stop functionality
• Commissioning: Hardware validation checksheets, functional testing, safety-critical validation, point-to-point verification
• Project Management: Phased delivery, RACI matrix coordination with site engineers, vendor representatives, and contractors