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Monday, June 26, 2017
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Customer Profile

Company
OAO Siberian Coal Energy Company (SUEK)

Technology Parter
Saga Inc.
VIST Group

Industry Name
Mining

Product Name

  • MWAN 6300 Series
  • PTP100 (2.4GHz) Ethernet Bridge

Solution Features

  • Self forming, self healing network
  • High mobile data rates
  • Secure, high-throughput connectivity
  • Sophisticated interference mitigation
  • small footprint, easy to install

Case Study - Motorola

Motorola Mesh Technology Chosen for Russian Mining Networks

Critical Data from Mobile Vehicles Demands High-Speed Wireless Solution
 
Since its formation in 2001, the OAO Siberian Coal Energy Company (SUEK) has grown to become the largest coal operation in Russia and ranks among the world’s top ten coal producing organisations, based on the amount of coal mined.

With several branches and subsidiaries scattered across this vast country, neighbouring republics and territories, SUEK had a requirement for a wireless network solution that would have the capacity to deliver critical operational information from specially equipped mining utility vehicles at numerous sites.

The company chose Motorola’s Mesh Wide Area Network (MWAN) technology as a result of its scalability, equipment reliability, high rate of data throughput and advanced product design. The network was supplied by Motorola authorised distributor in Russia, Saga Inc. and implemented by systems integrator and Saga partner, the VIST Group.

Data Collection Key to Operational Control and Management

SUEK initiated a programme to develop a centralised system – known as Karyer-Holding - whereby data from each mining and other company operation throughout the country could be monitored and analysed.

The company looked to implement multi-site, high-speed wireless networks for the rapid delivery of telemetry information such as location coordinates, traffic speed, operating parameters and various events from mobile mine vehicles including dump trucks, excavators, bulldozers, fuel tankers and other machinery. This information would be used to create an automated traffic dispatch and control system to provide remote monitoring from the company’s regional offices.

The networking solution would have to adhere to stringent international standards, provide seamless connectivity and offer excellent scalability and flexibility to cater for ongoing development, applications and increased usage - this was particularly important, taking into account the ongoing changes to the surrounding terrain as a result of mining operations.

MWAN Provides Robust High-Speed Platform for Information Delivery

Currently, networks have been implemented at the open-cut mines of Chernogorsk and East Beysk in the Republic of Khakassiya in central Russia and Novoshakhtinskoe in the Primorsk region between Vladivostok and Khabarovsk.

The Mesh networks comprise IAP 6300 (Solo) Intelligent Access Points and Mesh wireless routers which have been strategically placed to allow mobilityenabled access via some 250 vehicle-mounted wireless modems.

In these RF challenging environments, secure mobile communications are critical so the self-forming, self-healing and self-balancing nature of the Mesh network has been designed to provide reliable broadband connectivity with fast communication handoffs to support routing changes between vehicles.

As a result of the constant changes to the mining environments, the option of deploying cable was not just impractical, but also expensive. The Motorola solution was to provide additional connectivity through its PTP100 fixed wireless broadband (Ethernet bridge) system which is delivering aggregate data rates of 10 to 12 Mbps over a distance of 10 kilometres. This system is also used to link regional site offices to the mines.

And so severe are the weather conditions in these areas that Saga has developed a unique ‘chip heating’ solution which ensures the PTP 100 equipment continues to work, even in temperatures as low as -60°C.

With the networks providing 100 percent communication coverage, dispatch centre personnel now have access to data from across entire mining operations. The use of satellite positioning technology has also made it possible to track movements of mobile equipment inside the mines in real-time while in-vehicle equipment monitors everything from fuel use to road surface conditions.

The data transmitted to the dispatch centre is used in decision-making for operational processes, recommendations and forecasts, planning, costing and report preparation. It also provides a platform for automatic data exchange which can now be leveraged and integrated with other software applications – for example, managing and monitoring of personnel and the subsequent costs involved.

Future developments include using the networks for video monitoring and integrating remote and mobile users’ work stations via wireless access.

Reduction in Operational Costs, Strong ROI

Motorola’s Mesh Wide Area Network technology has allowed for the successful implementation of the Karyer-Holding automated traffic dispatch and control system. This has subsequently led to an improvement in production scheduling and a significant reduction in resource overheads, such as fuel use.

Raising the average level to which dump trucks are loaded (based on continuous monitoring of the load level) has resulted in an 8-10 percent increase in carrying capacity efficiency. In addition, a reduction in shift downtime by a factor of 2-3 has resulted in a 10-12 percent increase in productivity across the mining and transport areas, which has realised an annual cost saving of approximately $2.5 million.

This ability to calculate the economic effect of implementation makes it possible to shift the emphasis from the cost of the equipment to calculating the payback period of the solution.

 

For many mining enterprises today, the mining-and-transport dispatch system is one of the main tools for increasing productivity. The results were already evident during the first months of operation - from fuel and lubricant savings to more rational use of machinery to improved work safety. While the system is currently being used at the Chernogorsk and East Beysk open-cut mines, we plan to use it at all of the open-cut mines, loading and transport units and vehicle depots within SUEK."

Pyotr Opanasenko, Deputy Engineering Director at SUEK

Mesh Networks Help Coal Giant Boost Production

The OAO Siberian Coal Energy Company (SUEK) has rolled out networks based on Motorola's Mesh and fixed wireless broadband technology at its mines across Russia. This has allowed for the implementation of an automated traffic dispatch and control system for bolstering efficiencies and controlling costs across its operations.

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