Oaky Creek North: TX031 Substation Control System Overhaul
The Challenge
Glencore’s Oaky Creek North coal mining operation required a comprehensive overhaul of their TX031 substation — a critical 11kV distribution asset serving four 1000V pump outlets. The existing control system relied on aging protection relays and manual switching infrastructure, limiting operational visibility and presenting safety and compliance gaps against current mining standards. Deftec was tasked with modernising the entire electrical and control architecture while maintaining site safety protocols throughout the workshop refurbishment.
Our Approach
Deftec delivered a complete control system redesign centred on a ControlLogix PLC platform paired with Multilin 850 feeder protection and a 10-inch Redlion HMI. The overhaul included replacement of the high-tension circuit breaker with an ABB VD4 unit, upgrade of all limit switches and interlocking to Fortress standards, installation of a new remote switching pendant rated for underground coal mining, and full migration from 240VAC to 24VDC lighting for improved safety margins. Engineering documentation was updated throughout — from functional descriptions and PLC logic to detailed as-built schematics — ensuring the site inherited complete, current technical records. Factory acceptance testing validated all I/O modules, networking, and operational logic before delivery.
The Outcome
The overhauled substation now provides real-time outlet monitoring, integrated protection relay coordination, and remote control capability aligned with Oaky Creek North’s operational control network (OCN). The system transitions seamlessly into the site’s existing Citect SCADA environment, giving operators unified visibility across all four pump circuits. Enhanced safety interlocking and compliance-driven labelling reduce manual intervention risk and support the mine’s ongoing regulatory requirements.
Technologies and Capabilities
- PLC & Control: Allen-Bradley ControlLogix 1756 platform (L72 processor, EN2T Ethernet adapter, 32-point I/O modules)
- Protection & Monitoring: Multilin 850 feeder protection relay with advanced communications (Modbus RTU/TCP, DNP3, IEC 60870-5-104)
- Network Infrastructure: EDS-G509-T industrial Ethernet switch, dual SFP fibre connectivity, 12-port ST patch panel
- HMI & Visualisation: Redlion CR3000 10-inch touchscreen with OCN Citect integration
- High-Voltage Switchgear: ABB VD4 circuit breaker, Fortress interlocking system, Lexan safety guards
- Field Control: Custom coal-mine-rated remote switching pendant with 10m cable assembly
- Engineering Deliverables: Functional descriptions, updated electrical schematics, Factory Acceptance Testing protocols, complete dossier documentation