Cloudbreak Bigge Fuel Farm Control System

The Cloudbreak Bigge fuel farm control system supported a new facility for refuelling mining vehicles. Australian Control Engineering (ACE) programmed the programmable logic controller (PLC) and operator interface panel (OIP) for the site. The scope also included communications setup, equipment-interface logic and operator screens.

Fuel farm control system scope

The project formed part of the mine’s non-process infrastructure (NPI). In this case, the fuel farm provided a service for mining vehicles. ACE’s role focused on the control software and interfaces for the new facility.

• PLC programming: implement control logic to interface with site equipment.
• Communications: set up communications for the PLC and OIP.
• Operator interface: design and implement the OIP screens.

Documented integration challenges

The existing case-study document records several challenges. Together, they show why equipment details and site conditions matter to control-system delivery.

PLC and drive communications

The project called for the PLC to communicate with variable speed drives (VSDs) over PROFINET. However, the site drives differed from the unit used during office testing. The document records difficulty establishing communications with those drives on site.

For background on the protocol, see PROFIBUS & PROFINET International’s technology overview.

Delivery timing and retained settings

The delivery window was shorter than usual for a project of similar size. In addition, the case study records lost PLC setpoints after a power cycle during commissioning. These are useful considerations when planning test coverage for a fuel farm control system.

ACE’s mining infrastructure capability

This project illustrates ACE’s work at the boundary between control logic, field equipment and operator interfaces. It also connects with our broader focus on utility and industrial control systems across Australia.

For a related application, read our data-centre backup-generator fuel control case study. You can also explore ACE’s engineering approach.

Discuss your fuel farm control system

Planning a new installation or an upgrade? Contact ACE with your equipment list, control requirements and delivery constraints. We can then discuss the PLC, communications and operator-interface scope.