Flotation system modernisation for a gold processing and mineral recovery plant.
July 2026System Integration & Control Systems Design
Project and industry:
Moore Process Controls completed the modernisation of a flotation control system at a gold processing and mineral recovery operation by upgrading the obsolete Schneider Modicon Quantum I/O platform to the latest Schneider Electric M580 X80 architecture.
The project was designed to preserve the client's existing M580 PLC while delivering a modern, supportable, and expandable I/O platform capable of supporting long-term operational reliability.
Project location:
Gold mine.
Project Outcome:
Working within a tightly controlled four-day plant shutdown, Moore successfully completed the migration with minimal impact on production.
Key project achievements included:
• Replacement and rewiring of 536 I/O points within the shutdown window
• Migration from obsolete Modicon Quantum hardware to the latest M580 X80 I/O platform
• Complete redesign of electrical panel and PLC drawings using ePLAN
• PLC software updates incorporating the new I/O mapping
• Successful IFAT and EFAT validation prior to site implementation
• Re-establishment of communications with the plant's I/O server
• On-site operator training and system handover to support ongoing maintenance
The result is a modern, scalable automation platform that significantly improves maintainability while extending the life of the overall control system.
Biggest challenge and solution:
The project presented several technical and operational challenges.The existing flotation control system relied on ageing Modicon Quantum I/O hardware approaching end-of-life, with limited spare parts availability. In addition, the panel had no local HMI for monitoring, I/O tag documentation was incomplete, and the entire migration had to be completed within a strict four-day production shutdown.
To minimise risk, Moore adopted a phased migration strategy. Electrical panel layouts and PLC documentation were redesigned in ePLAN, while the PLC software was updated to accommodate the new I/O architecture. The revised system underwent comprehensive Internal Factory Acceptance Testing (IFAT) and Extended Factory Acceptance Testing (EFAT) before arriving on site.
During the shutdown, the team followed a carefully planned installation sequence, removing the obsolete hardware, installing the new M580 X80 I/O racks, rewiring all field connections, testing each stage, and completing Site Acceptance Testing (SAT) before commissioning and operator handover.
This structured approach ensured the project was completed safely, efficiently and within the available shutdown period.
Key technologies:
· Schneider Electric M580 X80 I/O platform
· Schneider Modicon M580 PLC
· ePLAN electrical design software
· PLC software upgrades and I/O remapping
· Internal Factory Acceptance Testing (IFAT)
· Extended Factory Acceptance Testing (EFAT)
· Site Acceptance Testing (SAT)
· Operator training and knowledge transfer
One thing we would do differently:
Future projects would benefit from earlier collaboration with the client on final I/O rack allocation and panel layouts, allowing space constraints and rack consolidation to be resolved before the design is frozen.
Unique Selling Point
Moore Process Controls delivers multi-platform automation migrations that simplify legacy system upgrades, providing clients with a single trusted partner to modernise ageing infrastructure while maintaining operational continuity and supporting future expansion.
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