Project Background

Client: BHP
Date: July 2020 – February 2024
Location: BHP’s Port and Mine Sites, Western Australia

BHP’s Process Control Network (PCN) Core and Distribution switches, vital for site-wide communications, had reached End of Life (EOL), posing significant operational risks. GTE were engaged to urgently upgrade these components to prevent outages and losses while enhancing cybersecurity, redundancy and reliability – all without disrupting production.

Challenges

The GTE team were engaged to upgrade BHP’s outdated and unsupported network switches, which frequently failed and jeopardised operational continuity. The project involved careful execution to avoid any disruptions to ongoing production at BHP’s Port and Mines. GTE also needed to enhance cybersecurity measures and ensure the new design offered increased redundancy and reliability across the network.

Approach and Solution

Network Redesign
We re-engineered BHP’s PCN network switch infrastructure at both mine and port sites, covering both Core and Distribution networks. This involved upgrading approximately 250 network switches, including CISCO IE4010, IE5000 and 9500 models.

Turnkey Implementation
Our team modified and re-designed over 600 technical drawings affected by the network changes. The project also included delivering all necessary technology design and test documents, ensuring a smooth transition.

Enhanced Network Architecture
The new network design transitioned to a Layer 3 environment, which provided improved network segregation and future growth capacity. Extensive testing was conducted to ensure hardware and software compatibility, minimising risks of production outages during the commissioning phase.

GTE upgraded over 250 network switches at BHP’s Port and Mines, redesigning 600+ drawings. Our team completed this complex project over 30 site shutdowns with zero production impact and a faultless safety record.

Results and Impact

Operational Security and Reliability
The upgrade eliminated the risks associated with unsupported network switches, enhancing the operational security and reliability of BHP’s Port and Mines. The standardised design also improved cybersecurity measures, providing greater redundancy and better support for future expansions.

Execution
The project was executed in stages over 30 site shutdowns, with no impact on production and zero safety incidents—testament to GTE’s meticulous planning and execution.

Outcome

GTE’s execution of the WAIO Process Control Network Upgrades has set a new standard for operational reliability and cybersecurity at BHP. The project not only addressed immediate risks but also laid the groundwork for future growth, ensuring BHP’s network infrastructure is robust and scalable. Our ability to deliver such a complex upgrade without disrupting production underscores our expertise in managing critical engineering projects.

GTE combines four key disciplines—Electrical Engineering, Control Systems, Functional Safety and Industrial Communications—delivering cohesive, multidisciplinary solutions for complex engineering challenges.