Modernization of a QMA System
A mining facility uses the QMA quality assurance and data acquisition system developed by feba to keep a complete record of the construction materials and fluids used underground.
Material tracking begins as soon as materials are delivered to the surface and extends through silos, bunkers, mixers, and conveyor systems all the way to the filled underground structure. The existing system, which dates back to 2005, needed to be upgraded to the current state of the art in terms of both hardware and software without compromising the traceability of existing processes. A particular challenge was the combination of a system landscape that had evolved over time, ongoing plant availability, complex interfaces with PCS 7, material tracking, document archiving, barcode processes, and the requirements for IT/OT segmentation, data backup, and long-term maintainability.
Gefeba designed a modern, modular system architecture for QMA based on virtualized computer systems. A self-contained system is planned for each of the system components BSA1, BSA2, AFL1, and AFL2, so that maintenance, updates, and future expansions can be performed on individual areas without directly affecting other system components. The new platform is based on two Proxmox servers with separate virtual machines for the database, applications, web interfaces, services, and legacy components. PostgreSQL is used as the central database; documents such as delivery notes and sample records are stored in a structured manner on external NAS storage.
A key component was the migration of existing QMA data. This includes operations, deliveries, block notifications, balance sheet data, configurations, user and permission information, as well as documents related to operations. At the same time, the existing QMA dialogs and reports were rebuilt as a web application. This allows authorized users to access dialogs, reports, and documents via a browser. Barcode scanners, barcode printers, and document scanners were integrated into the operational processes. Scanned documents are processed automatically, assigned to a transaction via barcode, and, if the assignment is ambiguous, transferred to a clarification process for the operator.
For the commissioning, gefeba planned for parallel operation between the old and new systems. During this phase, material flows, processing sequences, and operations are managed in such a way that the new QMA can be tested and gradually transitioned into full-scale production. Communication with the PCS 7 level takes place via the gefeba Telegram Manager TM5 and corresponding TCP/IP telegrams. At the same time, the old ibaPDA/Oracle-based data transfer was replaced with a direct, telegram-based connection as part of a long-term strategy.
To increase availability, gefeba implemented an ONLINE/STANDBY concept. The gefeba Runtime Manager handles the switching of active roles, prevents concurrent process execution, and enables both automatic and manually triggered switches. The database is kept in sync via streaming replication and WAL mechanisms; additionally, Proxmox Backup Server, NAS storage, and supplementary full backups ensure recoverability. The new network infrastructure separates the QMA network, process network, DMZ, ITC network, and PCS 7 plant bus via firewalls and defined communication paths. Monitoring, a service PC, remote access, and NTP time synchronization round out the operational and maintenance architecture.
With this modernization, the customer receives a technically up-to-date and significantly better-structured QMA platform. Material tracking remains traceable across existing operational processes, while the hardware, database, user interfaces, interfaces, document processing, and network connectivity are brought up to modern standards. The self-contained system structure for each plant section improves maintainability and reduces dependencies between plant areas. ONLINE/STANDBY operation, database replication, a backup strategy, monitoring, and segmented network technology create a robust foundation for long-term operation. At the same time, the new data model—with chambers, sections, and system-wide unique process and structure hierarchies—provides a stable foundation for future expansions and plant-wide analyses.
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We develop customized solutions—from analysis through the engineering phase to commissioning and support. Our focus is on maximum functionality, on-time delivery, and durability.
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