ETAP Real-Time Projects PT Newmont

System Description - Location

Copper-Gold Mine Sumbawa-Indonesia Project held by PT Newmont Nussa Tenggara (PTNNT)

ETAP Rep Symposium December 2005

Confidential

System Description - Process

Open Pit Mine Use Electrical Shovels and Mechanical Drive Trucks to Transport the Ore Handles Around 600,000 t/d of Ore and Waste 0.49% Copper and 0.39g/t Gold

ETAP Rep Symposium December 2005

Confidential

System Description - Process

From Primary Crusher Ore Transported on a 6.8 km Overland Conveyor In Concentrator Sag and Ball Mills Produce 32% Copper and 19.9 g/t of Gold Ore is Pipelined to Benette (port) for Sea Transport
ETAP Rep Symposium December 2005 Confidential

System Description - Electrical

Power Plant 4 Steam Turbine Generators 34MW each 9 Diesel Generators 5 MW each Power Plant Located Next to Benette Transmission 2 - 15kM Lines to Concentrator and Mine Substations

ETAP Rep Symposium December 2005

Confidential

System Description - Electrical

Concentrator Loads 4 Ball Mills (10K HP) and 2 Sag Mills (13.4 MW) Other Process Loads Including Pumps, Fans, etc. Mine Loads Shovels, Primary Crusher Motors, Township, etc.

ETAP Rep Symposium December 2005

Confidential

System Description - Electrical

ETAP Rep Symposium December 2005

Confidential

Why ETAP Real-Time for PT Newmont ?

ETAP Rep Symposium December 2005

Confidential

Process Time Losses

Repeated Productions Losses Faults caused by animals in the transmission system Load variation caused instability in the generators when operating at maximum load Too Much Load Variation Could not shed shovels, port, or other variable loads because never knew how much was shed
ETAP Rep Symposium December 2005 Confidential

Process Time Losses

Only Constant Loads Sag Mills, Ball Mills, Overland Conv. Process time lost if any of those loads tripped $300K+ lost every trip on those loads High Generation Cost Had to run many diesels generators during normal operation Keep spinning reserve high and improve reliability
ETAP Rep Symposium December 2005 Confidential

ETAP Real-Time - Solution

ETAP ILS Provides PTNNT Monitoring of each sheaddable feeder and load Right combination of loads to trip Unlimited Load Priority Tables i.e. Winter process changes and therefore load priority changes
ETAP Rep Symposium December 2005 Confidential

ETAP Real-Time - Solution

Load Shedding against: One steam generator trip Multiple generators trip Boiler trips

ETAP Rep Symposium December 2005

Confidential

Old SCADA Limitations

Costly to expand Low performance Limited trending and no reporting features Primitive calculations techniques i.e. wrong frequency display for 2 min when one Gen goes offline No remote control for line breakers and process loads

ETAP Rep Symposium December 2005

Confidential

ETAP Real-Time - Solution

Real-Time Monitoring provides PTNNT: Complete monitoring of the system Control of their transmission and distribution breakers Trending, archiving, reporting of main parameters: Frequency, generation, power transmission, power generation, energy consumption
ETAP Rep Symposium December 2005 Confidential

How was it accomplished?

ETAP Rep Symposium December 2005

Confidential

ETAP Real-Time - Project

Divided on Three Phases Phase 1 Modeling and system studies Communication network design and implementation Phase 2 Data collection system and ETAP RealTime setup Phase 3 Load shedding setup and installation
ETAP Rep Symposium December 2005 Confidential

Project Steps Phase 1

ETAP Model Verification Newmont already have an ETAP model System data sent to OTI office for model verification Metering Evaluation General Electric SR relays in place Studies data collection speed requirements Load variation
ETAP Rep Symposium December 2005 Confidential

Project Steps Phase 1

System Studies to determine: Steady and transient stability limits Max. allowable load shedding time Min. load to shed for certain events Triggers

ETAP Rep Symposium December 2005

Confidential

Project Steps Phase 1

Communication Network Design Best method of networking existing meters Determined meters to replace Report and drawings submitted to Newmont Communication Network Implementation Done in house by PT Newmont Engineers Replacement of 12 relays to URs for maximum data collection Phase 1 completion, about 3 Months
ETAP Rep Symposium December 2005 Confidential

Project Steps Phase 1

ETAP Rep Symposium December 2005

Confidential

Project Steps Phase 1

Data Collection System Setup OPC Server installation and setup Setup done at OTI offices Installation and tuning done onsite 1 week trip ETAP Real-Time Server Installation Done in conjunction with OPC Server setup

ETAP Rep Symposium December 2005

Confidential

Project Steps Phase 1

Primary and Auxiliary Console Setup Remote Control Playback Real-Time Monitoring Archive Server for Reporting Phase 2 Completion 2 Months

ETAP Rep Symposium December 2005

Confidential

Project Steps Phase 1

PLC Programming Trigger Handling Priority Table Handling Performed in OTI Tested Onsite by OTI and Newmont Engineers Timing Fine Tuned Onsite

ETAP Rep Symposium December 2005

Confidential

Project Steps Phase 1

ETAP ILS Server installed Separate from Real-Time Server for reliability purposes Trigger Communication Wired triggers to PLCs Routed some triggers using IP tunneling

ETAP Rep Symposium December 2005

Confidential

Project Steps Phase 1

Complete test of communication Monitoring ILS calculations with real system data Triggers tested Final SAT Phase 3 completion, about 3 months

ETAP Rep Symposium December 2005

Confidential