Dozer solution for Kazakhstan gold mine

Autonomous solutions specialist RCT has completed a project for Russian Cat® dealer Vostochnaya Technica (VT) on a fixed position rockbreaker in Siberia.

The pilot project involved commissioning ControlMaster® Teleremote on a fixed position BTI rockbreaker for a large Russian mining company at one of its operations in Siberia.

RCT also provided a Digital Vision Kit consisting of two fixed cameras and audio capability and a Fibre Optic Control Station (FOCS) located in site offices on the mine’s surface.

RCT’s Moscow-based CIS Business Development Manager Stephen Macarow said the rockbreaker was the latest RCT project to be completed at mines in the region.

“RCT was selected to carry out this project due to its experience in integrating automation technology in mining equipment of all makes and models,” he said.

“Operating the rockbreaker from the mine’s surface will safeguard machine operators while also giving them the chance to better utilise the machine’s capabilities.”

As well as installing its Teleremote technology onto the rockbreaker RCT’s bespoke solutions division Custom tailored the Teleremote package to the mining company’s specific requirement.

“RCT developed a unique auto-stow function at the request of VT and the mining company,” Mr Macarow said.

The auto-stow function means operators can simply push a button and retract the rockbreaker arm from the grizzly or steel grate over the ore pass and bring the machine to a parked position.

VT Technology Enabled Solutions Manager Alexander Voroshilov said the Rockbreaker project was the next good project with RCT which has benefitted the customer.

“In order to complete this turnkey project the VT Technology team has done big amount of work from equipment delivery from Australia to the mine site, Customs clearance, manuals translation and certification to on-site installation and commissioning under supervision of an RCT engineer,” he said.

“The key factor of the project success is the customer support and good collaboration with a partner, so we really appreciate our partnership with RCT and the customer assistance.”

RCT is continuing to provide ongoing technical and after-sales support to the mine site.

World-leading autonomous solutions specialist RCT has succeeded over a global Original Equipment Manufacturer (OEM) and completed a customised Teleremote project at an underground mine in Kazakhstan.

RCT’s solution was selected over a technology option presented by a major OEM as its ControlMaster® Teleremote solution could be tailored to the mine’s site-specific requirements.

RCT worked with local Cat dealer Borusan Kazakhstan to install and commission its ControlMaster® automation technology onto two Cat R1700G underground loaders and associated Automation Centres located within the underground mine.

The ControlMaster® Teleremote solution is now being utilised at the Ridder underground Tishinsky copper mine in north-eastern Kazakhstan by local mining company Kazzinc.

Going forward, RCT will manufacture the Teleremote technology for an additional twelve Cat R1700G and Cat R1300G underground loaders while Borusan Kazakhstan will install this equipment at the Tishinsky and Dolinnoye mines.

The Teleremote solution enables machine operators to control the machine from a secure station in the underground mine with the help of strategically placed cameras and sensors.

Teleremote technology enables machine operators to access the machine’s full range of functions that they would normally have if they were sitting in the machine’s cab.

The company has also supplied its new digital communications network RCT Connect and integrated it with the underground loaders.

RCT Connect is designed specifically for autonomous and Teleremote machine operations in underground mining environments and can provide low latency, consistent communications between command inputs from the mine’s surface and subsequent machine activities.RCT’s Moscow-based Business Development Manager – CIS Stephen Macarow said he is pleased to have completed the project in partnership with Borusan Kazakhstan.

“Our Teleremote solution means the operators will control the loaders from inside the Automation Centre and they will be protected from the hazardous conditions often found at the mine face including geotechnical risks, dust, exhaust fumes and temperatures as low as -27⁰C (-16.6⁰F),” he said.

“The mining company will also experience improved site productivity through reduced shift handover times and less unplanned maintenance downtime from machine operator errors.”

“The ControlMaster® Automation and Control solutions are fully interoperable and agnostic, it can be integrated into any machine make and model and carry out the same range of functions as promised by the OEM.”

“RCT has been supplying proven technological solutions to the mining industry in Kazakhstan and the broader CIS region for over 25 years and we look forward to providing more autonomous solutions in the future.”

A spokesperson for Borusan Kazakhstan said the company has been working with RCT since 2008 and in that time has delivered multiple automation projects for the Kazakhstan mining industry including at the Tishinsky mine.

“Borusan Kazakhstan has been actively watching the regional mining market and in cooperation with RCT has developed Teleremote technology that is suitable for the CIS market,” they said.

“In collaboration with RCT Borusan Kazakhstan currently provides remote control and Teleremote solution implementation, standard and adapted-for-the-customer equipment delivery, maintenance services and employee technology trainings.”

“At the start of 2020 we started work on the largest project to date with RCT to implement ControlMaster® Teleremote onto two Cat underground loaders and we look forward to implementing the additional 12 units over the course of the year.”

Borusan Kazakhstan equipment service engineer Altamirov Yegor said he has worked with RCT for 10 years and has enjoyed seeing the automation technology evolve to suit mining industry requirements.

“I believe that the key to RCT’s success is they listen to the wishes of each customer and the mine site staff,” he said.

“I have worked closely with RCT staff on joint technical solutions and in critical situations RCT instantly reacts and makes decisions to eliminate the problems.”

“Their work provides mining clients with dynamic development and ever improving automation systems.”

RCT has successfully completed its biggest project to date for Caterpillar dealer Vostochnaya Technia which has seen eight automation solutions deployed at Polyus’ Olimpiada surface mine in Krasnoyarsk region, Eastern Siberia, Russia.

The company’s bespoke department, RCT Custom successfully designed, manufactured and installed ControlMaster® Teleremote solutions tailored specifically for this project for a fleet of five Caterpillar 777F trucks, a Komatsu 1 PC-3000-6 hydraulic shovel and D-275A-5 dozer and an Atlas Copco DML drilling rig.

This project was a crucial turning point for the gold mine’s transition into an autonomous machine operation and will allow the site to operate more safely and efficiently.

The solutions allow operators at the gold mine, to simultaneously clean up landslip while continuing production in the same area; significantly increasing productivity by reducing downtime associated with manual operation of the mobile machines.

This is made possible thanks to the customisation of the Teleremote solution to incorporate the Multiple Machine Selection (MMS) feature which allows one operator to swap between machines when production tasks change.

This is particularly significant to aiding productivity as the mine operates 24 hours a day, seven days a week.

Prior to the installation of RCT’s automation solutions, the mobile machines were operating in hazardous areas prone to rock fall and exposed to extreme weather conditions all year round.

RCT’s customised Teleremote solutions removed the operator from the cab of the machines and relocated them to an ergonomically designed Control Station, complete with modern comforts such as heating, which is essential at a mine experiencing such extreme temperatures.

Two Control Centres were deployed on site, one controls the trucks, dozer and shovel and the second controls the drill.

Providing operators with a comfortable working environment has proven to increase productivity as they remain more alert during shifts.

As well as protecting operators from the elements, each component of RCT’s ControlMaster® solutions were specifically designed to withstand the extreme temperatures experienced in Russia.

As a result, all components are in compliance with ambient classification set forth in GOST 15150-69; ensuring components can operate efficiently in temperatures ranging from -45 degrees Celsius and 45+.

Visibility was another factor that had to be taken into consideration due to the mine’s location. To ensure seamless operation during the evening shifts and the winter months, additional external lighting was fitted to the trucks and loaders; ensuring adequate visibility during the mining process during these times.

This extensive project also required the reinvention of the design of RCT’s existing surface drill console which was installed to control the Atlas Copco drilling rig on site.

The drill console was downsized and thanks to the latest ControlMaster® technology the Custom department was able to reproduce it into a more manageable size with the same functionalities it previously possessed.

The console now consists of four joysticks which can be used over four different modes to perform 50 functions necessary to operate a surface drill via remote control.

It was also integral the drill icons would translate well to Russian but also have a universal meaning.

“Everything we have implemented on this console has been to serve a specific function. It was important we catered to every function the operator would have, as if they were in the cab of the machine,” said RCT’s CIS Business Development Manager, Stephen Macarow.

“RCT can provide more than a standard offer; it’s our agileness and ability to rise to any technological challenge that gives us that competitive edge,” Mr Macarow said.

To further ensure operators have the same, if not better view of the operating area, pan-tilt-zoom cameras – capable of remote directional and zoom control were added to the drill.

The end result was a modernised console that met all the criteria for this drill that will lay the foundations, to be adapted to various drills for years to come.

A Polyus spokesperson stated that the introduction of capabilities for equipment remote control improved safety of mining processes in challenging mining and geological conditions of the Olimpiada Mine. The project provided an opportunity to evaluate technologies and capabilities of remote control systems. And to begin work on assessing the possibility of using automated control systems to operate mining machines.

VT’s Technology Manager, Alexandr Voroshilov said: “for Vostochnaya Technica (VT) this project is not only the biggest technology project, it is a good example of strong partnership with RCT and good relations with our customer Polyus. The project involved 40+ employees from VT, RCT, Neman and Sercons working on different project stages, 4 tonnes of high technology RCT equipment was delivered from Australia to the remote mine site in Russia. It also encompassed specially designing and building 2 operator stations, obtaining 6 certification (permission) documents and it took 6 month for installation, full testing and commissioning. VT and RCT have been partners for more than 8 years, we worked as one team to complete this project and to provide a comprehensive solution to our customer.”

While RCT is prominently known for its work in the underground mining environment, its capabilities have always encompassed surface mines and this project is an excellent example.

RCT's Custom department's unique capabilities are often called upon to provide bespoke solutions to CAT dealer, VT and its clients in Russia.

This project highlights RCT’s interoperability capabilities; installing automation solutions on Caterpillar, Komatsu and Atlas Copco mobile machines and have them work together to achieve a common goal of increasing productivity safely.

RCT is proud to announce its latest project with Russia’s Caterpillar dealer, Vostochnaya Technica and Polyus.

This extensive project will see RCT’s Custom department design, manufacture and install eight ControlMaster® solutions for five Caterpillar trucks, a shovel, dozer and a drill.

Polyus will be utilising these machines equipped with RCT’s Smart Technology at its Olimpiada surface mine, near Krasnoyarsk in Russia. This project is the crucial turning point for the mine’s transition into an autonomous machine operation.

RCT’s Custom department’s unique capabilities are often called upon to provide bespoke solutions to Vostochnaya Technica and clients in Russia.

Stay tuned for more on this project…

In 2015 Russian CAT dealer Vostochnaya Technica approached RCT for a unique remote control solution to safeguard operators at Octyabrskaya, Komsomolskaya and Mayak mines in Russia.

The sites operated a wide range of CAT Loaders in their fleets and wanted to physically remove operators from the cab of the machines, particularly at the draw points where there was risk of rocks falling onto the loaders while digging. In addition to this, the operators needed to have better control of machines while operating on remote control.

It was decided the best solution to suit this application was RCT’s ControlMaster® Portable Teleremote system. Cameras were placed on board the loaders to provide operators with vision of the machines movements via a colour LCD screen positioned on the carry frame, and operators controlled the machine via remote control on the unit.