In early 2025, South Africa’s Limpopo province was hit by a rare convergence of natural and infrastructural crises. Torrential rains, coupled with the sudden collapse of the Bierspruit Dam near Swartklip, caused widespread flooding across the region – crippling operations at several mining facilities.
Among the hardest hit was Valterra Platinum’s Tumela Mine, part of the Amandelbult Complex. Thanks to swift action and robust emergency procedures, all personnel were evacuated safely and no injuries were reported. However, underground workings and the main pump station were inundated, halting production and threatening up to 10% of the company’s monthly metal-in-concentrate output.
Faced with mounting operational pressure, Valterra Platinum turned to ABB for urgent support to restore critical electrical infrastructure.
“When the flooding hit Tumela Mine, our first priority was the safety of our people and protecting critical infrastructure. Thanks to our emergency protocols, we were able to evacuate safely and avoid injuries, but getting operations back online quickly was essential. ABB’s rapid response and technical expertise was instrumental in restoring production without compromising safety,” said Isak Rudolph, Principal Engineer: Electrical and Automation from Valterra Platinum.
Fast-tracking recovery to restore operations
Within 24 hours, ABB mobilised a cross-functional response team from its Longmeadow facility in Johannesburg led by Jan van Zyl, Product Line Manager Primary Switchgear and Manie Jooste, Product Line Manager Secondary Switchgear. “We knew the stakes were high, not just for production but for safety and continuity. Our team came together quickly to design, build and deliver a solution that could get Tumela Mine back online fast,” said van Zyl.
Two key substations were identified for urgent recovery which housed both primary air-insulated and secondary gas-insulated switchgears. With extensive damage and no time for standard manufacturing lead times, ABB and Valterra Platinum worked together to fast-track a solution. ABB developed and delivered an accelerated 10-week production and commissioning plan to replace the damaged switchgear.
Thanks to seamless coordination, Factory Acceptance Testing was completed ahead of schedule, and ABB’s Electrification Service team was swiftly deployed to install and commission the new UniGear ZS1 primary air-insulated and SafePlus secondary gas-insulated switchgears, bringing operations back online within the planned timeframe. “Our switchgears are user-friendly and offers efficiency, reduced maintenance cost as well as a seamless integration with smart grid systems,” said Jooste.
A model for emergency engineering
This extraordinary effort not only brought Tumela Mine back online ahead of schedule, but also set a new benchmark for rapid engineering response under crisis conditions. The collaboration demonstrated the power of agility, precision and partnership in overcoming operational adversity.
“The Tumela Mine recovery is a powerful example of how ABB supports customers not just with technology, but with people who show up, solve problems and deliver results when it matters most. The entire project was executed without a single safety incident or lost-time injury, reinforcing our team’s commitment to putting safety first,” said Oliver Morton, Project Manager, ABB South Africa Electrification Service.
