The situation
Allmatic engaged Beetle Engineering as principal engineering contractor for two underground equipment overhauls at Anglo American’s Aquila Mine — a Pod Pump (GPU952) and an Auxiliary Fan (AAF001). Both machines required PLC and HMI programs updated from legacy software versions to the current platform, modified for new equipment numbering, and factory acceptance tested. The AAF001 fan also required integration of an Ampcontrol Gasguard mine atmosphere gas monitoring controller into the PLC and HMI via a Red Lion protocol bridge.
Our approach
Pod Pump:
- Converted PLC program to current software version, updating I/O configuration and adding a new analogue input card AOI.
- Upgraded PanelView HMI to current FactoryTalk View ME version, resizing pages, updating graphics, and adding undercurrent trip setpoint control.
- Conducted full FAT at Major Electrical workshop. Auxiliary Fan:
- Converted fan PLC program to current software version, updating I/O and adding Gasguard communications logic.
- Updated PanelView HMI to current version, replacing legacy gas monitoring pages with a new Gasguard page.
- Developed Red Lion Crimson program to read Ampcontrol Gasguard via serial and write gas data to PLC.
- Conducted full FAT across PLC, HMI, and Red Lion at Major Electrical workshop.
Outcome
Both units were fully programmed, integrated, and factory acceptance tested prior to underground deployment at Aquila Mine. Allmatic received complete program backups and FAT documentation for both units. The Auxiliary Fan project demonstrates Beetle Engineering’s capability to integrate third-party safety instrumentation — mine atmosphere gas monitoring — directly into machine PLC and HMI architecture using Red Lion as a protocol bridge.