Standardized Control Solutions for Safer, Smarter Mining Operations
- GPA
- 6 days ago
- 2 min read
A mining operation required a unified and configurable control solution for equipment used in ventilation and dewatering. Existing systems varied across sites, leading to inconsistent operation, limited diagnostics, and increased time spent troubleshooting. GPA delivered a standardized control platform designed to improve reliability, operator usability, and long-term maintainability.
The Challenge
The operation needed a control system that would:
Support both fan and pump functionality within a single panel design.
Offer multiple operating modes, including manual, automatic, timed cycles, and level-based control.
Provide clear alarms and operational feedback instead of basic run/stop indication.
Use a consistent communication structure across all installations.
Reduce commissioning effort and simplify field adjustments for technicians.
GPA's Solution
GPA delivered a complete PLC and HMI control package with a consistent structure that could be deployed across multiple sites and adapted to varying equipment needs. The platform allows operators to designate the system as either a fan controller or pump controller directly through the HMI.
1. Configurable Fan/Pump Operation
The control system supports two types of equipment through selectable configuration screens. This flexibility reduces hardware variation and enables uniform training and operation.
2. Clear, Operator-Friendly HMI Design
The touch-screen interface includes:
A main menu with overview information
Real-time status screens showing amperage, pressure/flow, and motor condition
Alarm banner and history
Trend screens for monitoring system behavior
Parameter menus for adjusting operating values
Role-based access control
These elements provide a clear and consistent user experience across all sites.
3. Comprehensive Operating Logic
The system includes complete logic for safe and effective operation of both fans and pumps.
Fan Logic Includes:
Failed-to-start detection
Pressure-based warnings and faults
Phase amp monitoring (high, low, differential)
Vibration switch warnings and fault capabilities
Pump Logic Includes:
Timed run mode
Time-of-day scheduling
Level-based start/stop using digital or analog sensing
Low-amp shutdown
Flow switch and external flow monitoring
This structure supports operational flexibility while providing consistent protection and feedback.
4. Built‑In Calibration & Setup Tools
To support commissioning and maintenance, the system includes on-screen tools for:
Scaling analog sensors
Performing 4–20 mA calibration
Viewing real-time raw and scaled values
These reduce reliance on specialized software changes in the field.
5. Standardized Communication Framework
All systems use a consistent Ethernet/IP communication layout, providing predictable device addressing and a network structure that can be repeated on additional sites as needed.
Results
Improved Safety & System Awareness
Clear warnings, faults, and diagnostic information enable operators to make informed decisions and maintain safer operation.
Consistent Operation Across All Installations
A single platform now supports all fan and pump panels, reducing variation and simplifying operator training.
Reduced Commissioning Time
Field teams can adjust parameters, calibrate sensors, and validate equipment behavior directly through the HMI.
Better Real‑Time Insight
Live data for amperage, pressure, flow, alarm activity, and system status provides meaningful visibility into equipment health.
Scalable Infrastructure
The consistent communication structure supports future expansion and integration with higher-level systems.
Conclusion
GPA’s standardized fan and pump control platform provided a mining operation with a reliable, flexible, and easy‑to‑maintain solution. By delivering consistent PLC and HMI functionality, configurable parameters, built-in calibration tools, and unified alarms, GPA helped streamline operations while laying a scalable foundation for future growth.
