Oaky North Coal: 54CT Diesel Compressor Backup Station
The Challenge
Oaky North Coal’s 54CT site required a complete backup compressed air and power generation solution to maintain operations during grid outages. The project demanded the design, supply, installation, and commissioning of four diesel compressors, a generator, fuel storage, control systems, and supporting infrastructure — coordinating multiple disciplines and equipment sourcing across a complex industrial site.
Our Approach
Deftec delivered a fully integrated control and automation solution centred on a custom IP66 stainless steel switchboard housing PLC systems, Modbus communications, and automatic transfer switching. We developed comprehensive PLC and HMI programming for a Cummins C33 generator with automatic start/stop on mains failure, integrated four Atlas Copco XAVS 1800 diesel compressors with individual gateway communications, and connected an ELGI EGRD2000 refrigerated dryer — all monitored and controlled through a Red Lion HMI and Citect SCADA interface. Our scope also included design and installation of 100mm galvanised rolled-groove compressed air pipework, a dual 10kL diesel fuel pod system capable of running the compressors for 48 hours between refuels, site electrical installation with 415VAC and 240VAC distribution, and full on-site commissioning with I/O verification.
The Outcome
The system went live with successful wet commissioning in May 2025, running the compressors automatically with stable start/stop control and accurate Citect indications. The backup station is now fully operational at Oaky North Coal, delivering reliable compressed air generation and uninterrupted power supply to the 54CT operation — with operators able to control equipment locally via HMI or remotely via SCADA, and automatic failover to diesel when grid power is lost.
Technologies and Capabilities
- Control Systems: PLC programming, Modbus RS485 communications, automatic transfer switching
- HMI & SCADA: Red Lion HMI development, Citect SCADA integration and updates
- Field Equipment: Generator control (Cummins C33 with Smart Gen HAT600N ATS), compressor gateway integration (Atlas Copco XAVS 1800), dryer automation (ELGI EGRD2000)
- Switchboard Design & Fabrication: IP66 stainless steel enclosures with DC charging, battery systems, and multi-compartment layout
- Mechanical Installation: Rolled-groove piping systems, fuel systems engineering, isolation valve design for safe maintenance
- Electrical Installation: 415VAC mains, 240VAC auxiliary, lighting, cable scheduling, and site compliance testing
- Engineering Documentation: Functional descriptions, cable schedules, mechanical isolation manuals, as-built drawings, and operational manuals