Rio Tinto/ BHP TLO Trim Chute Bar Automation

The objective of this project is to develop an automated control system for a hydraulic profile bar integrated with the Train Loadout chute. The system will enable the implementation of distinct loading profiles in accordance with the characteristics of the ore type and density. The profile bar will be manipulated to raise or lower based on predetermined setpoints tailored to the specific ore type and density. This optimization of the loading process will enable each loading wagon to attain optimal weight control, resulting in a boost to production throughput.

Rio Tinto Belt Rip Detection System

There are numerous types of belt rip detection systems on the market and each with its own limitations. An effective and easily maintainable solution was devised to enable belt rip detection by utilizing an array of distance sensing sensors. The system processes raw distance values and incorporates filtering to eliminate the impact of material deflections on the belt, as well as intermittent noise from dust and water sprays. A threshold algorithm is then employed to detect rip events. The outcome is a dependable system that deliver the resolution.

Newcrest Gold Mine Alarm Rationalisation

This project employs the Six Sigma methodology to optimize the HMI alarm system. The existing alarm was found to be suboptimal, leading to an excessive number of nuisance alarms that overwhelmed operators. This resulted in delays in attending to equipment shutdowns, adversely impacting production and equipment reliability in the long run. To address these issues, the alarm system was managed through a process of standardization, consolidation, elimination, and optimization. Standardization involved the implementation of streamlined and consistent processes and procedures for the alarm system to enhance its effectiveness. Consolidation was employed to reduce the number of alarms by consolidating similar or redundant alarms, resulting in reduced confusion and improved response times. Elimination was used to remove unnecessary alarms that did not provide actionable information, thereby enhancing the overall efficiency of the system. Optimization helped fine-tune the alarm system to ensure that the right alarms were triggered at the right time, with appropriate levels of escalation. As a result of these measures, a significant number of alarms were eliminated, leading to better operator focus on achieving production targets. The optimized alarm system is expected to enhance equipment reliability and improve production efficiency in the long run.

Newmont BAC PLC Logic Upgrade

The scope of this project involves converting the logic from ladder logic to function block diagram using site-specific DFB templates. The original program was designed as a vendor package, which does not align with the site's functional specifications. Therefore, this conversion requires incorporating programming standards that adhere to the site's control system functional specification. Before the code changeover, a pre-commissioning FAT was conducted. The result of the conversion was a smooth transition without any disruption to production.

MACH Energy Mine CHPP Design and Commissioning 

This involved in the design, control system programming, and commissioning of the CHPP processing plant. Liaised with clients to review system functional designs and oversee FAT activities. Responsibilities include the integration and commissioning of electrical equipment such as protection relay, VSD, remote I/Os, and network devices. Optimize the performance of the processing plant by utilizing techniques such as PID loop tuning, advanced process control schemes, and equipment configuration. Leading commissioning and production activities with a team of project and maintenance personnel. Prioritize safety in conjunction with ensuring that project deliverables are achieved to a high standard.

Whitehaven Coal Mine First-Up Alarm Implementation

Develop a first-up alarm system for all underground conveying equipment. The process involved identifying and resolving duplicate alarms to ensure effectiveness. Furthermore, standardizing HMI interfacing for alarming templates helped to reduce nuisance alarms and improve alarming efficiency. As a result of these measures, the alarm system was optimized, providing efficient monitoring of the equipment while minimizing disruptions caused by unnecessary alarms.

New Century Mine Process Improvement 

Leads commissioning activities and providing production support for process improvement. Development of sequencing code for various processing plant circuits, implementing process control strategies, and optimizing plant throughput. Identified maintenance and production bottlenecks to improve plant performance. One example of a process improvement was the implementation of cyclone valves operating capacity control. This involved determining the number of cyclones in operation based on pressure setpoints and tank level capacity, resulting in improved plant throughput consistency and reduced variability for downstream circuit controls. Additionally, individual cyclones were operated in a cycled timed manner to maintain even operating time, aiding in predictive maintenance and reducing unscheduled downtime.

Infrabuild Steel  

The project entailed the integration of a customized MES (Manufacturing Execution System) and PLC (Programmable Logic Controller). The MES system plays a crucial role in managing production orders, controlling inventory levels, and monitoring machine performance. On the other hand, the PLC facilitates the transmission and receipt of required data to and from the MES via a proprietary communication protocol. It is also responsible for receiving production orders and providing product tracking within the processing plant. The development of a dedicated HMI (Human-Machine Interface) interface is aimed at enhancing product tracking capabilities. The final product delivers improvements in manufacturing activities by increasing efficiency, reducing waste, and enhancing product quality.