Train Load-Out Upgrade – From Underperforming to Maximum Throughput /
PROJECT SUMMARY
Tier16 was engaged by a Tier-1 miner to assist in the upgrade of an existing Train Load-Out (TLO) facility. The TLO is a critical asset to the operations and over time, performance had reduced below acceptable limits.
Tier16’s upgrade focused on control system optimisation, process improvement, and reliability enhancements, ensuring the load–out operates at required throughput for at least the next 25 years.
CLIENT CHALLENGE
The client faced the challenge of restoring reliability and efficiency to a TLO system that had degraded over decades of incremental software changes. Over time, the system had become suboptimal, with fixes occasionally introducing new issues.
Limited documentation on the existing control system made problem identification and process improvement difficult.
The client needed a solution that could increase throughput, reduce downtime, and improve reliability while avoiding disruptions to train scheduling and operations.
TIER 16 solutions
Tier16 provided end-to-end control system design, development, integration, and commissioning, with a focus on process optimisation and long-term operational reliability. The team conducted a deep dive into decades of accumulated software, identifying the precise code that was causing performance degradation and inefficiencies. Using this insight, Tier16 developed a functional specification for an improved PCS implementation and optimised both the PLC and SCADA systems to ensure stable, efficient operation.
Detailed simulation software was developed to observe the behavior of the existing system. Once a thorough understanding of its operation was achieved, suboptimal sections of the software were identified for improvement.
In addition, the software was updated to incorporate upgraded mechanical components and pumping arrangements.
The process was rigorously tested through software simulation and full off-site Factory Acceptance Testing (FAT) in Jandakot, Perth with all new mechanical equipment. This validated the improvements and help avoid troubleshooting during on-site commissioning. Once deployed, the solution worked immediately upon start–up, transforming load-out performance and restoring full operational reliability from day one.
Tier16 transformed the TLO from underperforming and unreliable to the most efficient load-out on the line, increasing throughput, reducing downtime, and ensuring smooth train scheduling.
The project scope included:
TLO control system process optimisation
Simulation of TLO process to further understand existing process
Develop a functional specification detailing improved PCS implementation
PLC, SCADA Design review, modification and verification
Factory acceptance test documentation
Perform factory acceptance testing
Site acceptance testing documentation
Commissiong documentation
On-site commissioning
TECHNOLOGIES USED
Schneider PLC Quantum
Schneider Control Expert
Aveva Plant SCADA
TIA Portal Simocode ES
PROJECT OUTCOMES & IMPACT
Tier16’s upgrade delivered a transformational improvement in TLO performance. The load-out moved from being the lowest performing to the highest-performing on the line, with significantly reduced downtime and increased throughput, enabling more trains to be loaded without impacting scheduling.
Immediate Operational Success: By identifying and correcting the exact code causing performance issues, Tier16 ensured the solution worked immediately on-site, eliminating trial-and-error fixes and minimising operational risk.
Process Efficiency: Optimising the legacy software and control systems maximised operational efficiency, improving the speed and reliability of train loading.
Long-Term Reliability: The upgrade remediated structural and operational risks, securing safe and efficient TLO operation for the next 25 years.
Cost Savings: Improvements in uptime, throughput, and process efficiency delivered measurable cost savings and reduced unplanned maintenance.
