MINE MAINTENANCE
Smart water solutions
One of the more important pieces of infrastructure at open-pit mines is the haul road . This transport route keeps haul trucks moving and , when optimally maintained , can improve cycle times , and boost ore production and waste movement . Haul road dust , however , can take a toll on safety and productivity on site , leading to a continuous struggle to balance dust suppression with overwatering .
At MINExpo , Caterpillar introduced its new 777G Water Solutions truck to offer mining and quarry operations an innovative and smarter water truck to help control haul road dust . Caterpillar saw an opportunity to move into the water truck market , offering customers an integrated water solution .
This move , the company said , would provide a more efficient option for mining companies , as opposed to combining and assembling separate systems together . Caterpillar will also offer a full warranty over this truck , providing the peace of mind that , if there is a problem , the Cat ® dealer network will rectify it with parts supply or expert maintenance insight .
Built on a proven Cat truck platform , Cat Water Solutions integrates the truck , tank and water delivery system , and connects it with technology .
This technology leverages Cat MineStar Edge™ , a platform that creates an operational ecosystem for mining companies , allowing managers to see how activities early in the process impact those further down the value chain . Factoring in cloud computing and recent technology advancements – such as data fusion , machine learning and artificial intelligence – MineStar Edge continues to grow as it collects data , identifies patterns and learns to make decisions .
The Cat Water Delivery System ( WDS ), when combined with Cat MineStar Edge , can solve overwatering and underwatering issues with a focus on efficient and sustainable operations , according to the company . It provides data such as : n The water usage by truck / fill station ; n The volume of water distributed over time and the area covered ; n The rate of water distribution ; n An activity breakdown including time and distance ( watering , not watering , stopped , etc ); and n Operator reports on water coverage and need ( route , heat map , decay map , etc ). This information can drive improved operator productivity , improved water spray use , lower water costs and improved cycle time , according to Caterpillar .
“ Currently the market does not have a connected solution that addresses the specific features present in a dust suppression machine such as a water truck ,” the company said . “ Having a fully integrated watering control system , developed by Caterpillar , allows us to relay information on the watering system performance and health .”
Cat Water Solutions powered by MineStar Edge provides a flexible approach and may be used with other mine site technology or as a standalone system through a Wi-Fi or cellular connection , according to Caterpillar .
While the solution does not rely upon an overall site solution for other types of equipment , if an overall site solution exists , Edge may coexist at the site .
“ For example , an operator may continue to use the overall site solution to login , complete pre-start checklists , code delays , etc while Edge tracks water delivery ,” the company said . “ Or , if there ’ s not an overall site solution , Edge may be implemented as a complete solution including site-wide Equipment Tracking , load and haul Production Recording and Water Solution tracking .”
With Cat VIMS , haul trucks are already capable of measuring haul road condition issues via Road Analysis Control events . This information may be used when determining a need to send support equipment ( water truck , motor grader , dozer ) to address the haul road condition .
“ Anyone with access to the MineStar Edge web instance for the Cat Water Solutions truck can simply grab a web-capable device and have the status and operation of their watering asset immediately available ,” the company said .
“ Integration of Cat MineStar Edge with current Cat MineStar Telemetry solutions will bring all the Edge functionality and useability online to full MineStar users . And , along with it , our first-in-the-industry Cat Water Solutions connected content .”
The WDS , which includes a water cannon , oil cooler , variable displacement pump , hydraulic oil tank , electronic control boxes and hydraulic motor / water pump , uses all this information to optimise water delivery , providing variable waterflow based on truck speed , while determining the appropriate flow to reduce the risk of accidents due to poor visibility .
Caterpillar expanded on this : “ The variable displacement pump automatically starts and stops when the truck slows or comes to a halt , preventing overwatering and subsequent poor traction at road intersections . It also features soft start-ups and turns off automatically when the tank is empty , preventing damage to the system from the pump running dry .
“ Reducing health hazards associated with airborne particles , the automated water delivery system also allows the operator to remain focused on driving to enhance site safety . Remote tank fill control , complete with auto shut-off to prevent overfilling , enables the operator to remain inside the cab during refilling to reduce potential operator slips and falls .”
This system also helps address the skills gap the mining sector is currently experiencing .
“ The Cat WDS can run in Auto Mode , which allows a less experienced operator to be more efficient ,” the company explained . “ Auto Mode regulates the water spray so the desired coverage will be achieved regardless of truck speed or engine rpm . And , as a connected asset , data from the truck can be utilised to know where and when to water .”
The Cat WDS can , Caterpillar claims , reduce water consumption by 25-50 % compared with conventional water systems . Additionally , the efficient pump control reduces fuel consumption by an average of 14 %. The water cannon also operates at idle , which reduces fuel consumption during cannon operation by up to 50 %.
While the OEM says the Cat 777G Water Solutions truck can benefit mining operations globally , it sees strong regional opportunities in Australia , South America , South Africa and North America .
The 777G water truck is the first Cat Water Solutions offering . Additional models will be offered this year
44 International Mining | JANUARY 2022