Project Background
Client: BHP
Date: Ongoing since August 2022
Location: Yarnima and Mining Area C Power Stations, Pilbara, WA
BHP engaged GTE to upgrade their ageing high voltage SCADA systems, which were critical to operation of their 132/66/33/11kV networks but had become a liability. GTE was brought in for their expertise and successfully modernised these systems, improving both operational reliability and cybersecurity.
Challenges
The decentralised nature of the SCADA systems created operational inefficiencies and heightened risks. The lack of centralised monitoring led to potential production downtimes and increased vulnerabilities. This project required a partner with comprehensive technical knowledge and a practical approach to problem-solving—qualities our team at GTE is uniquely equipped to provide.
Approach and Solution
Engineering Expertise
At GTE, we leveraged our multidisciplinary expertise, integrating electrical engineering, control systems, functional safety and industrial communications all under one roof. This allowed us to deliver a cohesive solution that addressed both the immediate technical challenges and the long-term operational needs of BHP.
Tailored Implementation
Understanding BHP’s unique requirements, we focused on consolidating SCADA servers, upgrading communication systems and replacing obsolete hardware. Our Perth-based test lab played a crucial role in de-risking the project, ensuring that all solutions were rigorously tested before implementation. Our local presence and agile structure allowed us to respond swiftly and effectively, providing hands-on support that larger firms often struggle to match.
GTE overhauled a Tier 1 Mining Operator’s SCADA system in the Pilbara, replacing end of life equipment and standardising assets. We achieved a seamless Layer 3 migration with zero downtime, driving significant improvements.
Results and Impact
Operational Gains
Our solution significantly improved BHP’s operational efficiency, reducing system inefficiencies and enhancing cybersecurity. The streamlined SCADA system we implemented provided improved oversight and minimised the risk of production disruptions.
Strategic Impact
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
By delivering a reliable, future-proof system, we didn’t just solve BHP’s immediate problems—we positioned them for continued success. The project reinforced BHP’s operational stability and demonstrated the value of working with a company like GTE, one that understands both the technical and business aspects of engineering.
Conclusion
Our work on the NPI HV SCADA Upgrade Project showcases our ability to deliver complex, forward-thinking engineering solutions. Our multidisciplinary approach and complete understanding of BHP’s operations ensured the project’s technical and strategic success. As we continue to support BHP, this partnership is set to drive further innovation and collaboration. With a commitment to quality and practical involvement, GTE is an invaluable partner for Tier 1 companies seeking a collaborative approach that truly meets their needs.
WA-owned and independent, GTE’s hands-on directors offer technical expertise and oversight to every SCADA upgrade, ensuring your systems are modernised and secure.
