Crusher and mill SCADA upgrade
Phased replacement of legacy SCADA with a modern, documented platform — preserving historical trends and improving alarm rationalisation.
Industry · Mining
Process, electrical and monitoring engineering for hard-rock and bulk operations.
PLC, SCADA, MV and LV electrical, telemetry and OT cybersecurity for crushing, milling, washing, conveying, pumping, ventilation and tailings — built for the duty cycles, environments and compliance regimes mining actually runs in.
Industry Challenges
Mining operations are unforgiving — to people, equipment and integrators.
Vibration, dust, water, distance and 24/7 duty cycles eat poorly engineered systems alive. Add MHSA compliance, energy cost, community pressure and tailings risk, and the margin for error vanishes. Promation SA delivers automation and electrical work that survives the environment and stands up to the audit.
Unplanned downtime cost
Every hour of conveyor, mill or pump downtime costs production that cannot be made up later in the month.
Power and energy intensity
MV reticulation, large drives, motor health and demand management directly drive both safety and unit cost.
Remote and distributed assets
Pumps, fans, weighbridges and substations spread across kilometres with limited connectivity and harsh access.
Safety & compliance pressure
MHSA, environmental and tailings regulations demand documented controls, interlocks and records.
Ageing automation estates
Mixed PLC and SCADA estates accumulated over decades with limited documentation and support paths.
Skills and shift coverage
Specialist control and electrical skills hard to retain on site, especially out of metro areas.
Common Operational Problems
What we hear from the plant floor.
01
Conveyor and mill trips with no clear root cause
Hours of production lost while teams hunt through alarms, with no time-aligned data to explain what actually happened.
02
Pump stations failing remotely with no alarm
Flooded sections, environmental incidents and emergency response costs that dwarf the price of telemetry.
03
MV protection and earthing that hasn't been reviewed in years
Latent arc-flash and fault-current risk to crews, plus insurance exposure that only surfaces during the next event.
04
SCADA running on unsupported operating systems
A single hardware failure stops production, with no documented recovery path and no certified backup.
05
Tailings and water systems monitored manually
Compliance exposure, environmental risk and shift-team workload that should be automated and continuously logged.
06
OT networks flat, unsegmented and exposed
A single phishing email or contractor laptop one infection away from stopping plant production for days.
07
Energy consumption and motor health invisible
Tariff optimisation, predictive maintenance and ESG reporting all blocked because the data simply isn't being captured.
Promation SA Solutions
How we solve them.
01
Process control modernisation
PLC, SCADA and HMI upgrades for crushing, milling, washing, conveying and pumping — documented and supportable.
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MV & LV electrical engineering
Reticulation, protection, MCC, drive and earthing studies and remediation across surface and underground operations.
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Remote asset monitoring
Telemetry for distributed pumps, fans, substations, tailings and weighbridges with structured alarming.
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OT network & cybersecurity
Segmented, redundant industrial networks aligned to IEC 62443 — protecting production from external and internal threats.
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Integration to MES & ERP
Production, tonnage, energy and quality data flowing to SAP, mine planning and metallurgical accounting systems.
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Tailings & environmental monitoring
Instrumentation, telemetry and reporting for tailings dams, water balance and environmental compliance.
Explore serviceBenefits
Outcomes we engineer for.
Lower downtime cost
Structured fault handling, alarm rationalisation and remote diagnostics cut response and resolution time materially.
Higher throughput
Tighter control loops, better drive coordination and real OEE visibility lift sustainable throughput.
Safety & compliance
Interlocks, protection studies and audit-grade records aligned to MHSA, environmental and insurer expectations.
Audit-ready data
Time-stamped, tamper-resistant production, energy, water and tailings records ready for regulators and stakeholders.
Example Use Cases
Representative engagements.
Illustrative use cases that typify the kind of work Promation SA delivers in this sector.
Dewatering pump telemetry network
Remote monitoring and alarming across dozens of dewatering and tailings return pumps, slashing emergency callouts and flood risk.
MV protection study and remediation
Site-wide protection coordination, arc-flash and earthing review with prioritised remediation programme.
Conveyor energy and condition monitoring
Motor current, vibration and temperature monitoring across critical conveyors feeding a structured planned-maintenance loop.
Tailings dam instrumentation
Piezometers, level, flow and CCTV instrumentation with automated regulator-aligned reporting.
OT cybersecurity programme
Network segmentation, secure remote access, asset inventory and IEC 62443-aligned hardening across a multi-site operation.
Why Promation SA
The right partner for mining.
Engineering depth, sector familiarity and single-contract accountability — the combination most operators in this industry struggle to find.
Site-hardened engineering
Designs and panels built for mining duty — dust, vibration, surge, temperature and 24/7 cycles.
Safety-first culture
MHSA, OHS Act, permit-to-work and safety-file discipline are part of how we operate, not a bolt-on.
Multi-vendor capability
Genuinely vendor-agnostic across Siemens, Rockwell, Schneider, ABB and others — including mixed legacy estates.
Remote-operations ready
We design for connectivity-constrained sites by default — store-and-forward, redundant paths, low-bandwidth dashboards.
FAQ
Common questions.
Do you work on operating mines without disrupting production?
Yes. We plan around production windows, use permits, parallel-running strategies and shutdown work, and design phased cutovers that protect tonnes-per-hour.
Can you handle MV up to 22 kV?
Yes. Our electrical capability covers LV and MV networks up to 22 kV — protection studies, switchgear, transformers and earthing systems by qualified engineers.
How do you secure OT networks in mining?
Aligned to IEC 62443: zoning and conduits, segmented industrial networks, hardened remote access, asset inventories, monitoring and incident response playbooks.
Can you support sites without permanent fibre or cellular?
Yes. We design for satellite, point-to-point radio, LoRaWAN and store-and-forward edge gateways so distributed assets remain monitored.
Do you work with our existing PLC and SCADA estate?
Yes. We work across Siemens, Rockwell, Schneider, ABB and Mitsubishi, including bringing mixed legacy estates under unified SCADA, historian and reporting layers.
Do you provide ongoing support?
Yes. Support contracts include remote monitoring, on-call engineering, scheduled site visits and structured continuous-improvement reviews.
Can you produce documentation suitable for MHSA and insurer audits?
Yes. As-built drawings, protection studies, test results, change logs and CoCs are core deliverables — not optional extras.
Book a Consultation
Discuss mining with a senior engineer.
Start with a free 15-minute discovery call. We'll review your situation and outline practical next steps — at no cost.