Conveyor 220-CV-205 Test Report

For
El Abra Chile

Tested by Luis Suazo, Allan Baus

Reported by Karl Liao, Nicole Hampton
Date: Mar.14, 2007

1. Tests Summary:

Conveyor 220-CV-205 of El Abra Mine is driven by four 900kw wound rotor induction
motors. Each motor is equipped with secondary resistor components and contactors
(SRC) for starting acceleration control. There are large vibrations during conveyor
starting.

We (Synergy Chile) checked the resistance of the SRC units for all motors in Jan, 2007
and tested the conveyor starting in Jan. and Feb.2007. All resistances were measured
using a Milli-ohm meter and AC welder. The rotor current of all motors were monitored
by a chart recorder during conveyor starting. The recorded charts were analyzed.

Here is the summary of the test results.

1. There are large mechanical vibrations at all step change during the whole
conveyor starting time. It will cause serious damage to the motor and the
mechanical system over time.

2. The starting sequences are different from the original design. Four seconds are
used for all steps. Torque jump at step change is over 32% of motor full load
torque (FLT). This contributes to the vibrations.

3. Four motors change step concurrently and apply maximum 128% of motor FLT
torque change to the conveyor. This is the main cause of the vibration during the
step changes.

4. The minimum starting torque of the motor is 81% of FLT. Motor 1 and motor 2
energize first and then motor 3 and motor 4. The total torque applied to the
conveyor is 162% of motor FLT at the first step.

Synergy Engineering Ltd Page 1 3/20/2007

Confidential
 5. The belt tension control system is not stable. There are large belt tension
fluctuations during the whole conveyor starting.

6. There is 20% of load unbalance between motor 2 and motor 4.

7. Resistor overheating is observed. Multiple starts will result in heating that exceeds
legal mine standards of 375C.

2. Test Results Details

2.1 Motor and Resistor Information

Motor: 900KW, 998rpm

Primary voltage/Current: 6600V/92.5A
Secondary Voltage/Current: 1380V/395A
The resistance at 100% loads at 100% slip: R100=7.449 ohm.
The full load rotor current peak =395*1.414=558 Amps.

Six contactors and six resistors are used for starting, one extra contactor functions as a
start shorting circuit contactor. The resistors of three phases are connected in Delta.
There are some permanent resistors that are shorted out during starting and are
connected into the circuit only when the start finishes. (See drawing at picture 1)

The designed resistors for each phase are:

K011 K012 K013 K014 K015 K016 Total/phase

ohms ohms ohms ohms ohms ohms ohm

0.1184 0.2368 0.474 0.947 1.885 3.788 7.449

Total 18 steps (0-17) and 60 seconds were designed for starting. (See the table inside of
picture 1)

2.2 Resistance Tests:

We checked the resistance of the secondary resistors for all motors in Jan, 2007. The
brushes of the motors were removed to isolate the motor from the resistors. The
resistance was measured when the contactors were in different configurations. Two
methods were used. Method A was to use an AC welder and multi-meter to read voltage
and current, and then calculate the resistance. This method can help find any bad
connections under high current, but the measured values are not accurate. Method B was
to use the milli-ohmmeter to measure the resistance directly. Please see the table on
picture 2 for the results.

We also checked the resistor temperature after the conveyor start finishes and physically
checked the resistor cabinet.

Synergy Engineering Ltd Page 2 3/20/2007

Confidential
We concluded from the test results:

1. The resistances among three phases for all motors in all configurations are
balanced.

2. The maximum resistance deviation among three phases for all motors is 0.055
ohm that is only 1.4% difference.

3. The resistances among four motors in all configurations are very close in range.
For example, the resistance of motor 1 has 3.998 ohm and motor 4 has 3.940ohm,
which is about 1% difference.

4. All cables and resistors are connected properly and all resistors are in working
condition. Any failure of the connections or resistors will result in resistance
deviation among phases or motors.

5. Resistor overheating occurs. Resistor overheating marks were observed on the

cabinet Over 330 C was recorded after starting once (See picture 3). Multiple
starts may cause resistor heating and cause potential hazard.

2.3 Conveyor Starting Test Setup

The conveyor is started at about 80% load condition. One phase of rotor current for four
motors was monitored with a chart recorder. Total four channels were used. The motor
current and torque are calculated from the recorded charts.

When the rotor current is within 0-125%, it is linear to the motor torque; as a result, we
use the rotor current percentage as motor torque percentage. The real wave is indicated
on the chart and the peak of the rotor current is used to calculate the percentage of the
rotor current.

2.4 Conveyor Starting Sequence

Based on the information from the recorded chart, we summarized the starting
performance indicated on the table (picture 4)

A. The starting sequences dont match the design indicated on original drawing (see
charts on picture 5). Total 18 steps (0-17) and 68 seconds are used for starting.
The time on step is 4 seconds for each step. This causes higher torque change on
some steps and higher resistor heating on other steps.

B. Higher torque changes occur during the first several steps. The torque changes in
step 2 reaches 39% of FLT (see chart 6). We normally control the torque change
at various steps to be less than 25%.

Synergy Engineering Ltd Page 3 3/20/2007

Confidential
 C. Four motors change steps concurrently during the whole starting. The charts
clearly indicate four motors step change. (See chart on picture 7). This is the main
cause of the large mechanical vibration, because the torque change applied to the
conveyor is four times of one motors torque change during step change. Four
motors can be changed the step at different time so that only torque change of one
motor is applied to the conveyor (refer to picture 12).

D. When the conveyor initially starts, motor 1 and motor 2 energize and then motor 3
and motor 4 energize after 0.7 seconds. (See chart on picture 8).

E. The minimum starting torque is 81% of FLT(torque at first step). This matches
the resistor design. (see chart on picture 8)

The rotor current peak is: M1: 475A; M2: 430A;M3: 420A; M4: 470A
Rotor current peak = 450 A (refer to chart 8)
Rotor Current RMS value = 450/1.414 = 318A = 81% 0f 395A
Average peak=450A, R= 318 =81% of 395A

2.5 Belt Tension:

The video of the conveyor starting clearly indicates that the belt is loosening and
tightening at each step. It cause large belt tension and motor load fluctuations.

It is indicated from the chart (chart on picture 9) that the rotor current reduces-increases-
decreases, which reflects the tension and motor load reduce-increase-decrease.

2.6 Load Unbalance

There is 15-20% load unbalance among four motors as shown in picture10. For Example,
motor 4 has current 84A and motor 2 has 96A when the conveyor is normally running.
(Picture 11)

3. Recommended Solutions

The large vibration and belt tension fluctuations during conveyor starting will cause belt
slip and serious damage to the motor and the whole mechanical system. The higher
torque jumps during starting and unstable belt tension contribute to this issue. We can
improve the starting performance greatly through the following actions.

There are engineering calculation and PLC programming modifications involved with
item 1-3. New resistors and SRC are required for item 4 and 5 which may not be
mandatory. With these actions, we can achieve a much smoother starting similar to what
we provided for Escondida as indicated on charts on picture 12 and 13.

Synergy Engineering Ltd Page 4 3/20/2007

Confidential
1. Stagger four motors about 1-2 seconds during energization and the whole acceleration
sequence; this will greatly reduce the torque changes applied to the conveyor at step
change.

A. Staggering four motors during acceleration reduces the torque changes to the
mechanical system to 1/4. When the motors are started staggered, only the torque
of one motor is added to the belt gradually (1/4). Also, the step changes for each
motor group are staggered, resulting in smaller torque changes to the belt during
the acceleration sequence. Since four motors energize and change steps at
different times, the actual starting steps are increased from 18 steps to 72=4*18
steps. Compare the picture 12 with 13; it is clear that the staggering starting
provide a much smoother starting.
B.
C. Staggering is mechanically and electrically acceptable for the motor and the
gearbox. When the motor is not energized, it (and the gearbox) can turn freely at
regular speeds without braking the system. When not energized and rotating,
current is not flowing in the rotor circuit.

D. Staggering four motors upon energization reduces the current inrush to one of
four motor at a time. Because of the nature of the secondary resistive controller
(SRC), the energization inrush of each motor is limited to < 1 second. Staggering
motors on a common power system reduces the overall effects of the limited
inrush.

2. Check the take-up winch control system and make sure the tension is within proper
range. When the motor is starting at certain step, if the tension and load is stable, the
motor should increase speed steadily and the rotor current should be reduced
gradually (like the chart on picture 14).

A. Disable any tension adjustment during starting.

B. Increase tension to the proper range before starting.

C. Energize the motors on the secondary pulley first and then the motors on the
primary pulley during staring. The proper sequence should be: motor 1 on
secondary pulley-motor 1 on the primary pulley -motor 2 on the secondary pulley
-motor 2 on the primary pulley.

D. Make sure there is no material feeding during conveyor start-up.

3. Redesign the starting time on each step so that a smooth starting can be achieved.
The torque jump can be smoothed by adding time to the steps with high torque spike,
and the resistor heating can be reduced by shorting the time on the step with much
less torque and speed change.

Synergy Engineering Ltd Page 5 3/20/2007

Confidential
4. Add new load sharing resistors to reduce the load unbalance among motors. The new
resistors can be manually adjusted to add resistance to the motor with higher load. As
a result, the load on this motor can be reduced. The load unbalance among four
motors should be less than 5%.

5. Replace the existing resistors with new stainless resistors, increase the total resistors,
so that the minimum starting torque can be reduced from 81% to our standard 30-
40%, suitable for conveyor applications.

Synergy Engineering Ltd Page 6 3/20/2007

Confidential
Picture 1 - Resistor and Starting Sequences Design
 Picture 2- Resistances Tests
Picture 2-EI ABRA CONVEYOR 200-CV-205 RESISTNACE TEST

Motor M1

Welder Ohmetro Welder Ohmetro Welder Ohmetro Actual Deviation (Ohms)

X-Y Ohmetro X-Z Ohmetro Y-Z Ohmetro U-V V-W W-U

Action 3.287 3.990 3.294 3.990 3.283 3.990 0.000 0.000 0.000

K16 1.492 1.937 1.502 1.936 1.527 1.932 0.001 0.004 -0.005

K16,K15 0.731 0.949 0.728 0.944 0.733 0.944 0.005 0.000 -0.005

K16,K15, K14 0.377 0.440 0.380 0.439 0.383 0.438 0.001 0.001 -0.002

K16,K15, K14,K13 0.000 0.193 0.000 0.194 0.000 0.193 -0.001 0.001 0.000

K16,K15, K14,K13, K12 0.000 0.066 0.000 0.067 0.000 0.067 -0.001 0.001 0.000

K16,K15, K14,K13, K12 , K11 0.000 0.001 0.000 0.001 0.000 0.001 0.000 0.000 0.000

K16,K15, K14,K13, K12 , K11 y K10 0.000 0.001 0.000 0.001 0.000 0.001 0.000 0.000 0.000

Motor M2

X-Y Ohmetro X-Z Ohmetro Y-Z Ohmetro U-V V-W W-U

Action 3.232 3.997 3.262 3.997 3.240 3.998 0.000 -0.001 0.001

K26 1.542 1.938 1.546 1.935 1.523 1.937 0.003 -0.002 -0.001

K26,K25 0.745 0.948 0.737 0.946 0.735 0.947 0.002 -0.001 -0.001

K26,K25, K24 0.386 0.441 0.363 0.439 0.377 0.443 0.002 -0.004 0.002

K26,K25, K24,K23 0.000 0.194 0.000 0.194 0.000 0.194 0.000 -0.001 0.000

K26,K25, K24,K23, K22 0.000 0.067 0.000 0.066 0.000 0.067 0.000 -0.001 0.000

K26,K25, K24,K23, K22 , K21 0.000 0.001 0.000 0.001 0.000 0.001 0.000 0.000 0.000

K26,K25, K24,K23, K22 , K21 y K20 0.000 0.001 0.000 0.001 0.000 0.001 0.000 0.000 0.000

Motor M3

X-Y Ohmetro X-Z Ohmetro Y-Z Ohmetro U-V V-W W-U

Action 3.190 3.997 3.190 3.997 3.190 3.997 0.000 0.000 0.000

K36 1.505 1.936 1.505 1.939 1.514 1.936 -0.003 0.003 0.000

K36,K35 0.713 0.946 0.713 0.945 0.720 0.945 0.001 0.000 -0.001

K36,K35, K34 0.377 0.440 0.377 0.440 0.377 0.440 0.000 0.000 0.000

K36,K35, K34,K33 0.000 0.194 0.000 0.194 0.000 0.194 0.001 0.000 0.000

K36,K35, K34,K33, K32 0.000 0.067 0.000 0.067 0.000 0.067 0.000 0.000 0.000

K36,K35, K34,K33, K32 , K31 0.000 0.002 0.000 0.002 0.000 0.002 0.000 0.000 0.000

K36,K35, K34,K33, K32 , K31 y K30 0.000 0.002 0.000 0.002 0.000 0.002 0.000 0.000 0.000

Motor M4

X-Y Ohmetro X-Z Ohmetro Y-Z Ohmetro U-V V-W W-U

Todos abiertos 3.238 3.995 3.185 3.994 3.218 3.940 0.001 0.054 -0.055

K46 1.543 1.943 1.528 1.935 1.533 1.937 0.008 -0.002 -0.006

K46,K45 0.735 0.952 0.735 0.952 0.727 0.949 0.000 0.003 -0.003

K46,K45, K44 0.384 0.443 0.384 0.443 0.384 0.439 0.000 0.004 -0.004

K46,K45, K44,K43 0.000 0.193 0.000 0.193 0.000 0.193 0.000 0.000 0.000

K46,K45, K44,K43, K42 0.000 0.067 0.000 0.067 0.000 0.067 0.000 0.000 0.000

K46,K45, K44,K43, K42 , K41 0.000 0.001 0.000 0.002 0.000 0.001 -0.001 0.001 0.000

K46,K45, K44,K43, K42 , K41 y K40 0.000 0.001 0.000 0.001 0.000 0.001 0.000 0.000 0.000

Synergy Engineering Ltd. Confidential 3/14/2007 Page 1

 Picture 3-INFORME DE TERMOGRAFA N
N OT T Componente 332C
AREA Ripios
T Adyacente 206C
EQUIPO 220CV205 motor electrico #2
Diferencia 125.59
COMPONENTE Banco de resistencias

ADYACENTE Prioridad

N Imagen Fecha Hora

Emisividad D.Objeto T. Amb. F.Carga
Ir_300107_ 1/30/2007 1:10:24 PM
0.76 1.5 m 20.0C
007.jpg

326.6C

SP01 300

AR01 250

200
Photo
150

100

50

33.5C
Label Value
SP01 206C

Diagnstico

2/14/2007 3 Motor #2
 Picture 4 - Starting Performance
Picture 4- EI ABRA Conveyor 200-CV-205

Starting Performance

Step actual time Resistor Operating Time Rotor Current Peak Maximum Current Motor Torque Conveyor Torque
on step on each step Begin. Of step End of Step Torque Peak Change Change Change
(seconds) (Seconds) (amps) (amps) (TFL) (amps) (TFL) (TFL)

K011 K012 K013 K014 K015 K016

R0 R1 R2 R3 R4 R5 0
0 4 4 4 4 4 4 4 450 450 0.81 450 0.81 1.61
1 4 4 4 4 4 0 4 600 540 1.08 150 0.27 1.08
2 4 4 0 4 0 0 4 650 560 1.16 110 0.20 0.79
3 4 4 4 4 4 4 0 740 630 1.33 180 0.32 1.29
4 4 0 4 0 4 4 0 720 610 1.29 90 0.16 0.65
5 4 0 4 4 0 4 0 700 550 1.25 90 0.16 0.65
6 4 4 4 0 0 4 0 650 500 1.16 100 0.18 0.72
7 4 4 4 4 4 0 0 680 520 1.22 180 0.32 1.29
8 4 4 0 4 4 0 0 600 450 1.08 80 0.14 0.57
9 4 4 4 0 4 0 0 550 450 0.99 100 0.18 0.72
10 4 4 0 0 4 0 0 550 420 0.99 100 0.18 0.72
11 4 4 4 4 0 0 0 580 450 1.04 160 0.29 1.15
12 4 4 0 4 0 0 0 580 520 1.04 130 0.23 0.93
13 4 0 0 4 0 0 0 580 400 1.04 60 0.11 0.43
14 4 4 4 0 0 0 0 500 420 0.90 100 0.18 0.72
15 4 0 4 0 0 0 0 520 400 0.93 100 0.18 0.72
16 4 4 0 0 0 0 0 500 400 0.90 100 0.18 0.72
17 0 0 0 0 0 0 0 500 400 0.90 100 0.18 0.72

Total Time 68 52 44 40 32 20 12
 Picture 5- all Starting Steps

+1 M1(CH1)[V]
[V] M2(CH2)[V]
M3(CH3)[V]
M4(CH4)[V]
CH1 (100mV/DIV)

CH3
M1

CH1

CH4

CH2

-1

-95s -90s -85s -80s -75s -70s -65s -60s -55s -50s -45s -40s -35s -30s -25s -20s -15s

Picture 5- All Starting Steps

 Chart 6- Torque Change at Step Change

+1 M1(CH1)[V]
[V] M2(CH2)[V]
M3(CH3)[V]
M4(CH4)[V]

CH1
CH1 (100mV/DIV)
M1

CH4

-1

-85.5s -85.25s -85s -84.75s -84.5s -84.25s -84s -83.75s -83.5s -83.25s -83s -82.75s -82.5s -82.25s -82s -81.75s

Picture 6 - Torque Change During Step Change

 Four Motors Change Steps Concurrently

+1 M1(CH1)[V]
[V] M2(CH2)[V]
M3(CH3)[V]
M4(CH4)[V]

CH3
CH1 (100mV/DIV)
M1

CH4
CH1

CH2

-1

-91s -90.99s -90.98s -90.97s -90.96s -90.95s -90.94s -90.93s -90.92s -90.91s -90.9s -90.89s -90.88s -90.87s -90.86s -90.85s

Picture 7 - Four Motors Change Steps Concurrently

 Chart 8- Initial Start

+1 M1(CH1)[V]
[V] M2(CH2)[V]
M3(CH3)[V]
M4(CH4)[V]

CH4
CH1 (100mV/DIV)

CH2
M1

CH3

CH1

-1

-95.85s -95.8s -95.75s -95.7s -95.65s -95.6s -95.55s -95.5s -95.45s -95.4s -95.35s -95.3s -95.25s -95.2s -95.15s -95.1s -95.05s

Motor 1 and 2 Energize First Motor 3 and Motor4 Energize after 0.7 S

Picture 8 - Motor Inital Start

 Unstable Belt Tension

+1 M1(CH1)[V]
[V] M2(CH2)[V]
M3(CH3)[V]
M4(CH4)[V]

CH4
CH1 (100mV/DIV)
M1

CH2

CH3

CH1

-1

-91s -90s -89s -88s -87s -86s -85s -84s -83s -82s -81s -80s -79s -78s -77s -76s

Picture 9 - Belt Tension Unstable

 Load Unbalance among Motors

+1 M1(CH1)[V]
[V] M2(CH2)[V]
M3(CH3)[V]
M4(CH4)[V]

CH2
CH1

CH4
CH1 (100mV/DIV)
M1

CH3

-1

-16.25s -16s -15.75s -15.5s -15.25s -15s -14.75s -14.5s -14.25s -14s -13.75s -13.5s -13.25s -13s -12.75s -12.5s

Picture 10 - Motors Load Unbalance

Picture 11 - Motors Load Unbalance
 EXISTING

PICTURE 12 APPLIED TORQUE WITH EXISTING STARTING SEQUENCES

Synergy Engineering Ltd.

EL ABRA CHILE
4 X 900 KW Wound Rotor Induction Motors with Secondary Resistors for Conveyor CV205

Motor Torque and Applied Torque to the Conveyor with the Existing Starting Sequences
motor1 ,2,3,4

1.5
1.4
1.3
1.2
Torque ( %FLT of Per Motor)

1.1
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Start Timing (Second)
 RECOMMENDED
PICTURE 13 APPLIED TORQUE WITH STAGGERING STARTING

Synergy Engineering Ltd.

EL ABRA CHILE
4 X 900 KW Wound Rotor Induction Motors with Secondary Resistors for Conveyor CV205

Applied Torque to Conveyor with Recommended Staggering Starting Sequences

1.3
1.2
1.1
1
Torque (%FLT of Per Motor)

0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0 10 20 30 40 50 60 70 80
Start Time (Second)
 Picture 14 - Synergy Proposed Starting Sequences Sample

Synergy Engineering Ltd.

Escondida S2W9 Conveyor 222-CV-2A
4 x 1200KW Wound Rotor Motors and SRCs
DATE: Jan.11.06 S2W9-CV2A-TRC
For Proposal Rev.A
motor1
Motor Torque at Fully Loaded Belt motor2
motor3
motor4
2.4
2.2
2
Torque ( %FLT of Per Motor)

1.8

1.6
1.4

1.2
1
0.8
0.6

0.4
0.2

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95
Start Timing (Second)

Synergy Engineering Ltd.

Confidential 1/18/2006 Page 4
 Picture 15 - Synergy Proposed Conveyor Starting Performance Sample

Synergy Engineering Ltd.

Escondida S2W9 Conveyor 222-CV-2A
4 x 1200KW Wound Rotor Motors and SRCs
DATE: Jan.11.06 S2W9-CV2A-TRM
For Proposal Rev.A

Torque at Design Condition

Applied Torque to the System Torque at Empty Belt

2.4

2.2

1.8
Torque ( P.U. of FLT Per Motor)

1.6

1.4

1.2

0.8

0.6

0.4

0.2

0
0 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96
Start Time (Seconds)

Synergy Engineering Ltd.

Confidential 1/18/2006 Page 5
 Extened Tension Built up Steps
S

+1 Rotor Current_
[V] Rotor Current_
Rotor Current_
Stator Current

CH2
CH1 (100mV/DIV)
Rotor Current_U

CH1

CH4

CH3

-1

0s 2s 4s 6s 8s 10s 12s 14s 16s 18s 20s

Picture 16 - Synergy Proposed Starting Performance with Proper Tension System