Highlights:

• Wireless Alternative to Fiber: Replaced fiber-based infrastructure with a Point-to-Multipoint (P2MP) radio solution, ensuring stable connectivity across the smelting complex.

• Seamless DCS Integration: Enabled uninterrupted communication between the Distributed Control System (DCS) and multiple remote sites.

• Eliminated Downtime from Cable Cuts: Overcame frequent fiber disruptions by providing a robust, wireless data backhaul.

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‍Overview:

Our client is one of India’s leading integrated producers of zinc, lead, and silver, with a strong footprint in the mining and metals sector. Operating across a network of mining, smelting, and refining sites, the company is committed to driving efficient and sustainable resource extraction and production processes.

To support their complex operations spread across vast plant areas, they needed a reliable, robust, and scalable point-to-multipoint wireless communication solution; one that could seamlessly connect dispersed locations and streamline their operational workflows.

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Challenges & Requirements

To streamline operations across their expansive smelting complex, the client outlined several critical requirements for the new communication infrastructure:

• Uninterrupted Connectivity: A stable and continuous network was essential to connect their Distributed Control System (DCS) across multiple sites, overcoming the limitations of traditional cabling, which was prone to damage and disruption from harsh environmental conditions.

• Reduced Maintenance Overhead: Frequent fiber cable cuts led to high maintenance and repair costs. The client needed a more resilient solution that would significantly lower these ongoing operational expenses.

• Scalability and Speed of Deployment: With evolving operational demands, the client sought a solution that could be implemented rapidly and scaled effortlessly as new units and locations came online.

• Industrial-Grade Reliability: Given the demanding conditions of the mining and smelting environment, the network had to offer exceptional reliability and withstand extreme industrial stress, ensuring seamless data flow and operational control at all times.

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Solution:

To meet the client’s need for a highly reliable, cost-effective, and scalable communication network, we implemented Cisco’s Ultra-Reliable Wireless Backhaul solution. Leveraging the Cisco FM3200B-HW as the base station and FM4200F-HW as subscriber radios, the solution established a robust point-to-multipoint wireless network that eliminated the challenges of frequent fiber cuts while delivering high-performance connectivity tailored to harsh industrial environments.

Our team at Velocis adopted a methodical approach to design and deploy a network capable of supporting mission-critical operations across the smelting complex:

• Site Survey and Planning: We conducted a comprehensive site survey to evaluate bandwidth requirements and ensure clear line of sight (LOS) between the central radio and remote units. Optimal antenna locations were identified, with installations at heights of 10–15 meters to overcome physical obstructions and ensure uninterrupted communication.

• Frequency Planning and Interference Mitigation: Proper frequency bands were selected based on the site’s conditions, and channels were carefully planned to minimize interference and maximize network performance.

• Antenna Selection and Alignment: Antennas were chosen based on coverage needs and signal strength requirements, followed by precise alignment to maintain robust wireless links across all units.

• Point-to-Multipoint Architecture Deployment: Using Cisco’s Fluidmesh technology, we deployed a central FM3200B-HW base station and FM4200F-HW remote radios across the site. This architecture was thoroughly tested and optimized to ensure seamless, high-reliability communication between all remote locations and the DCS building.

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Business Outcomes:

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The deployment of Cisco’s Ultra-Reliable Wireless Backhaul solution delivered substantial benefits across operational efficiency, scalability, and cost-effectiveness:

• Seamless Operations with Zero Downtime: By eliminating disruptions caused by frequent fiber cuts, the wireless network ensured uninterrupted data flow between operational units—critical for maintaining control systems and smooth day-to-day functioning.

• Reduced Maintenance Overhead: The shift away from fiber infrastructure dramatically lowered maintenance and repair costs, enhancing overall cost efficiency and freeing up resources for strategic initiatives.

• Future-Ready Scalability: The flexible, modular nature of the solution enables easy expansion, allowing the client to connect new sites or scale up operations without significant infrastructure changes.

• High-Reliability Connectivity: Continuous, stable communication between all remote locations and the central DCS ensured operational continuity and real-time data access in an environment where reliability is paramount.