How To Safely Run A Power Plant

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1 WMEA Presentation May 29, 2014 Managing Power Demand on Excavators Craig V Fredrich Engineering Technical Steward Caterpillar Global Mining ERS / DGL Product Group

2 Contents Safety Introduction Caterpillar AC History Robust Power Requirements Power Demand Management Summary Questions 2 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

3 Safety 3 / Caterpillar Confidential: Green / WHEREVER THERE S MINING

4 Safety First, Safety Always Emergency Phone Numbers Fire Emergency: Call 911 Medical Emergency: Call 911 CPR/AED Certified? Who will call emergency numbers? Room Hazards - Chairs Location of Exits Nearest Fire Extinguisher Nearest AED Evacuation Point 4 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

5 Introduction 5 / Caterpillar Confidential: Green / WHEREVER THERE S MINING

6 Craig Fredrich Electrical engineer 28+ Years Mining experience Started in field service working on SCR based analog machines Have been with the progression of the drive systems to the present IGBT digital controls 6 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

7 Caterpillar AC History 7 / Caterpillar Confidential: Green / WHEREVER THERE S MINING

8 37 YEARS CATERPILLAR AC EXPERTISE Bucyrus forms alliance with Siemens. Bucyrus introduces GTO AC Drives Electric Rope Shovels Small Draglines Large Draglines (Swing) Bucyrus develops first AC IGBT/AFE Gearless 8750 Zhungeer (CHINA) Bucyrus AC IGBT/AFE Conventional Geared 8200 Reliance (INDIA) 8200 Reliance (INDIA) Bucyrus introduces Analog SCR AC Drives Electric Rope Shovels Small Draglines Bucyrus introduces IGBT/AFE AC Drives 495BII Large Draglines (Swing) Bucyrus AC IGBT/AFE Conventional Geared 8750 Lake Lindsay (AUS) 8750 TAU (CAN) 8 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

9 IGBT AC Drive Systems 180 plus machines approaching 8,000,000 operational hours IGBT powered Electric Rope Shovels operating since machines approaching 200,000 operational hours IGBT powered Draglines operating since new machines IGBT powered 8200 Draglines go to work / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

10 Robust Power Requirements 10 / Caterpillar Confidential: Green / WHEREVER THERE S MINING

11 Robust Power Requirements Electric Rope Shovels have a very high rate of change in power demand To reduce energy costs, rope shovels also regenerate electricity back onto the line A robust power system is required to manage both the regeneration and the high ramp rates These requirements provide challenges for Diesel power systems 11 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

12 Robust Power Requirements Rope shovel rate of change are 2 to 3 times faster than a typical Diesel generator can provide To protect the generator from regeneration, resistive load banks burn off excess energy 12 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

13 Power Demand Management How it Works 13 / Caterpillar Confidential: Green / WHEREVER THERE S MINING

14 Power Demand Management How it works Peak Shaver Shaves peak demand by using energy stored in ultra capacitors Power supplied by ultra caps Ramp Rate Limiter Redistribution of power for ideal genset loading Power stored in ultra caps Dig Swing & dump Lower

15 Electric Rope Shovel Typical Power Demand 15 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

16 Power Requirements with Power Management System Peak Shaver Shaves peak demand by using energy stored in ultra capacitors Ramp Rate Limiter Redistribution of power for ideal genset loading Regeneration Recharge ultra-capacitors with energy from stopping motions 16 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

17 Power Demand Management - On-Grid 17 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

18 Intellectual Property Power Demand Management U.S. Patent No. 4,358,719 U.S. Patent No. 8,174,225 U.S. Patent No. 8,536,814 Future Patents Pending

19 Dragline Typical KW vs Time curve 19 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

20 Dragline Typical KW vs Time curve Peak Shaver Shaves peak demand by using energy stored in ultra capacitors 20 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

21 Power Demand Management Overview 21 / Caterpillar Confidential: Green / WHEREVER THERE S MINING

22 Cat Power Demand Management Technology Caterpillar Exclusive Technology Off-Grid Benefits Most efficient off-grid power solution available Shovel operational on 4MW of genset power for reduced fuel consumption compared to traditional method of operating with 8MW of power or more Patented technology manages energy Rope shovel regeneration power utilized not wasted Sustainable solution Reduced greenhouse gas emissions Less wasted energy Additional Benefits after Power Grid is in place Trail cable flexibility longer trail cable runs Substation sizing reduced power infrastructure costs 22 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

23 Power Demand Management Trail Cable Sizing Longer trail cable* allows for more flexibility when placing substations Keep substation out of the pit Less hassle relocating during laybacks Remove the need to run high tension cable in the pit *Trail cable length is dependent upon many factors, including voltage drop of the transformer and overhead line. 23 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

24 Demonstrations at Tucson Proving Grounds 24 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

25 Power Demand Management Building Blocks 25 / Caterpillar Confidential: Green / WHEREVER THERE S MINING

26 System Components Transformers AFEs Inverters Incoming Power Hoist Propel Crowd Swing Chopper Energy Storage 26 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

27 Equipment Pictures 27 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

28 MRC Features Durable / Resilient Cabinets Durable welded steel construction Designed for ERS shock and vibration environment All components in cabinet are accessible for maintenance Degree of protection Ventilated section IP21 in acc IEC 529 Non-ventilated section IP54 in acc IEC529 Ambient temperature Normal Operation -40 C to + 50 C Storage & Transportation -40 C to +70 C Integrated and independent liquid cooling system Integral propel Transfer Switch 28 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

29 AC Power Module Building Blocks Dragline Skid Configuration Space for up to four AFE rectifiers Common DC bus Connects AFE with inverters Space for up to five motor inverters to power Maximum one 824AC hoist motor Maximum one 824AC drag motor Maximum one 822AC swing motor Conventional 1370W (4-4-4) Powered with 4 MRCs Conventional 1370W (4-4-4) Powered with 4 MRCs Ground Fault Protection DC Link Capacitor Precharge Transformer Delta / Wye Crowbar Aux Power Swing Inv 1 M Swing Motor 1 AFE 1 AFE 2 AFE 3 AFE 4 Hoist Inv 1A Hoist Inv 1B M Hoist Motor1 Drag Inv 1A M Drag Inv 1B T T T T Drag Motor 1 M Propel Motor 1 29 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

30 Power Demand Management Power Problems / Application 30 / Caterpillar Confidential: Green / WHEREVER THERE S MINING

31 Genset Challenges Regen Absorption Avoid engine overspeed Peak Power Limiting Limit engine sizing Rate of Change Match engine dynamic response Application without Peakshaving can require double the number of gensets needed with peakshaver 31 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

32 Mine Power Considerations Unstable Power Mines experience machine downtime or component failure due to insufficient or unreliable power infrastructure Delayed Power Plan Delays in the mine power plan cause delay in machine production Pit Expansion Expanding to an area of the mine that does not have electrical infrastructure 32 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

33 Greenfield Mine Application Mines have limited options for loading tools when opening a new pit until electrical infrastructure is in place at the pit Diesel-powered machines are typically employed for initial overburden removal Operating electric rope shovels on Diesel-generators is generally not economical due to the machine s excessive rate of change in power demand, unless peak shaving technology is employed Electric rope shovels also regenerate electricity, which can not be absorbed by generators and must be absorbed by PDMS or burned off via load banks 33 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

34 Mine Development with Diesel-Powered Machines Pre-Stripping Power Grid Complete Production Pros + Flexibility / Utility + Lower Initial Capital Cost per machine Cons - Higher Cost / ton - Lower NPV - Higher Total Cost 34 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

35 Mine Development with Power Demand Management Pre-Stripping Power Grid Complete Production Pros + Lower Cost / ton + Longer machine life + Backup Generators + Best TCO Cons - Higher Initial Capital Cost - Generator Cost 35 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

36 Holistic Machine Approach 36 / Caterpillar Confidential: Green / WHEREVER THERE S MINING

37 Holistic Machine Approach CAT Total Machine Commitment 37 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

38 Holistic Approach Examples House Ventilation Study Propel Study Roller Load Study Stability Study 38 / Caterpillar Confidential: GREEN / WHEREVER THERE S MINING

39 Questions? THANK YOU

40 Close Thank You For Your Participation 40 / Caterpillar Confidential: Green / WHEREVER THERE S MINING

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