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  • Fuel Consumption Monitoring for Heavy-Duty Mining Machinery

Fuel Consumption Monitoring for Heavy-Duty Mining Machinery

of heavy-duty mining machinery
Integrator was tasked with supplying the company, which is engaged in mining rare rocks, with a fuel consumption monitoring system.
Country: Kazakhstan
Industry: Mining, extraction of precious and non-ferrous metals and minerals
Year: 2018
Client: Business Engeneering Kazakhstan (Almaty, Karaganda)
Equipment:

Escort TD-150 fuel level sensors, Azimuth, Galileosky trackers. Software – own and Azimuth

The customer's task is to monitor fuel consumption of special mining equipment

Integrator was tasked with supplying the company, which is engaged in mining rare rocks, with a fuel consumption control system.

Previously, the company often encountered cases of theft and overuse of fuel, which resulted in excessive costs and, consequently, reduced profits from operations.

The integrator had to find a solution to manage fuel consumption outside GSM/GPS coverage areas.

Specifics of operation of special equipment

The customer’s fleet consists of several dozens of special vehicles for mining industry (CATERPILLAR and SCAMEC):

  1. crawler excavators
  2. mining dump trucks
  3. bulldozers
  4. loaders
  5. soil compactors
  6. underground machines for charging boreholes (PMZSh).

In such conditions, when equipment is in mines (outside GSM/GPS) standard solutions are not suitable. The human factor affects fuel consumption even more.

Therefore, vehicles need to be equipped with non-standard telematics devices and be monitored regularly.

Solution of the fuel consumption monitoring task on special equipment

  1. Escort TD-150 Fuel level sensor
  2. Azimuth Wi-Fi Trackers
  3. GalileoSky trackers with offline monitoring and upload of saved archive via USB
  4. Own Azimuth software
  5. DFM Fuel flow meter, Azimuth
Escort TD-150
Fuel flow meter DFM
Azimuth Wi-Fi Tracker
GalileoSky

Example of installation and operation of the equipment on machinery

Filling, expenditure and drain data recorded by the sensors are transmitted to the monitoring system via Wi-Fi or transferred to the monitoring system by regular uploading via tracker’s USB port.

Examples of fuel consumption reports before and after the implementation of the fuel consumption control system

Results of implementation of the fuel consumption control system on special equipment

Before the fuel control system was installed, about 8-10% of the fuel was stolen before it got into the tanks of machinery. After installation, this value was reduced to 0-2%. If we compare these figures in money: 15 756 814 – 1 995 589 = 13 761 231 tenge. (2,457,362 rubles)

That is, at the cost of diesel fuel 190 tenge/l (34 rubles/liter), in October the fuel was drained for 5 443 975 tenge (972 138 rubles).

As a result of the introduction of the fuel consumption control system for special equipment, fuel consumption was reduced by almost 1/3 (31%).