Moranbah North Mine: PCS Coverage & System Optimisation
The Challenge
Moranbah North Mine’s Coal Handling and Preparation Plant (CHPP) required sustained PCS (Process Control System) engineering support to maintain plant availability and resolve complex control system issues across multiple production circuits. The operation needed dedicated on-site expertise to manage a growing backlog of work orders, troubleshoot VSD parameter configurations, and oversee a major Citect SCADA platform rollout across the facility.
Our Approach
Deftec deployed a dedicated PCS Engineer to Anglo American’s Moranbah North Mine for a 26-week engagement (December 2023 - June 2024), providing continuous on-site coverage to support the CHPP’s control systems. Our engineer worked systematically through the work order backlog while handling urgent operational issues — from VSD phase and speed parameter investigations across multiple pump, crusher, and conveyor drives, to troubleshooting communications faults and refining SCADA graphics. Key deliverables included completing a comprehensive Citect migration, resolving tag mapping issues in new flotation and product transfer circuits, updating equipment travel limits on stackers and reclaimers, and implementing offset adjustments for mill operation setpoints. We also conducted detailed investigations into specific failure modes (such as loading issues on the FNP9755 circuit) and upgraded hardware where needed, including PLC card replacements in critical control racks.
The Outcome
Over the engagement period, the team completed 18 work orders per fortnight and cleared a significant portion of the notification backlog, enabling Moranbah North to progress capital and operational improvements without control system constraints. The Citect rollout was successfully completed on 16 October 2024, improving visibility and control across all major circuits. By combining preventive troubleshooting with reactive problem-solving, Deftec helped stabilise plant operations and provided the CHPP with a documented, optimised control system platform to support future productivity improvements.
Technologies and Capabilities
- PLC Programming & Configuration: Siemens automation platforms (MNMC, MPMC, MPSU controller systems)
- SCADA Systems: Citect HMI design, tag mapping, graphic development, and platform migration
- VSD Control: Parameter investigation and tuning for variable speed drives across pump, crusher, and conveyor circuits
- Instrumentation & I/O: Analogue and digital signal mapping, sensor troubleshooting, run-hour tracking
- Industrial Networking: Communications diagnostics and hardware replacement in control racks
- Process Circuit Support: Coal handling, grinding, flotation, and product transfer optimisation
- On-Site Engineering: 26 weeks dedicated on-site coverage for continuous availability and rapid issue resolution