The situation
As part of an ongoing underground equipment overhaul programme at Anglo American’s Moranbah North Mine, multiple machines required their PLC and HMI programs updated to the latest site backup versions, modified to reflect correct equipment numbering, and their network switches configured with correct IP addressing — all verified by formal Factory Acceptance Testing before going underground.
Our approach
- Updated Emerson RX3i PLC programs to the latest versions of site backups, modifying equipment numbering to match each unit’s identity.
- Updated QuickPanel+ HMI programs to correspond with the updated PLC configurations and correct equipment numbering.
- Configured Cisco industrial network switches with correct IP addressing and network parameters for underground deployment.
- Attended the Major Electrical workshop to perform physical PLC and HMI configuration, I/O testing, and functional verification.
- Developed and executed a formal FAT document capturing configuration information, I/O test results, and sign-off records for each unit.
Outcome
Each underground equipment unit was successfully programmed, configured, and FAT-tested at the workshop prior to dispatch, providing Anglo American and Major Electrical with documented verification of correct operation. Beetle Engineering’s in-house Proficy ME Integrator licensing enabled the work to proceed without additional software procurement. This engagement is representative of ongoing support to Major Electrical across Bowen Basin underground mining equipment programmes.