Engineered Solutions forMaterial Handling

R O U N D T H E G L O B E , S Y N E R G Y I S M A K I N G I T S M A R K

as the leader in the development of technologically advanced

Engineered Drive Systems and as an end-to-end electrical systems

provider for large-scope projects in the mining and material handling industries.

Delivering safe, reliable, efficient, and cost-effective drive solutions, Synergy

is a full service systems integrator with a demonstrated expertise in power dis-

tribution, drive systems, and instrumentation and control.

Since its inception in the 1980s, Synergy Engineering, based in Vancouver,

BC, Canada, has developed its core competencies in four continents, bringing

new cost-efficiencies to some of the world’s biggest mining operations, includ-

ing Chile’s Minera Escondida Ltda., and Syncrude Canada Ltd.

“Synergy provides a complete electrical package, including the drive control

systems and motors that power these massive crushers and conveyors,” says

Rick Neuman, P.Eng., Founder, President and Chairman of the Synergy

Engineering Ltd. Group.“Our company has become successful because we pro-

vide solutions that work, and we do it on time, for a lump sum, at a fixed price.

Synergy takes on full responsibility for the project and takes the risk away from

the client.

“We have a lot of satisfied

customers and we get a

tremendous amount of repeat

business because of our relia-

bility. We’ve had zero equip-

ment failures to date in the

Secondary Resistive Controller

and Wound Rotor Induction

Motor packages that we’ve

engineered.”

The core of Synergy’s drive business is an innovative SRC/WRIM technology

developed by Neuman. Secondary Resisters Controllers are drives that are

engineered to control Wound Rotor Induction Motors applications. Synergy has

made a name for itself by engineering these lower life-cycle-cost and highly

A▲ Four conveyor drive stations,

controlling a total of ten 1200kW

motors for the E1 expansion at

Minera Escondida Ltda.

YNERGY generally involves all three aspects of its

business activity in its large-scope projects.The three

business units—Power Distribution, Drives and Motors,

and Instrumentation & Control—work cooperatively on

major projects, but each unit also functions as a stand-

alone business.

One example of

a stand-alone

power distribution solution is Vancouver

International Airport, where Synergy was engaged

in the design and supply of substation switchgear.

Stand-alone solutions for Instrumentation, Control

and HMI are ably illustrated by Synergy’s work for

Gibraltar Mines to replace the existing Mine

Concentrator control system (Fisher Provox DCS) with a

DeltaV control system, complete with new DeltaV I/O,

two dual head control room operator stations and one

mobile remote wireless operator control station.

Synergy’s work included design, panel manufacture and

assembly, configuration conversion, installation, commis-

sioning and start-up support.

▲ Power Distribution: design and supply of

substation switchgear for Vancouver International

Airport.

Delivering safe, reliable, efficient,and cost-effective drive solutions, Synergy is a full service systems integrator with a demonstratedexpertise in power distribution,drive systems, and instrumentation and control.

2

▲ Instrumentation, Control and HMI for mine concentrator

control system at Gibraltar Mines, British Columbia, Canada.

Cente

rm

Gib

rala

tar

Min

es

▲ Power Distribution: design and supply of four

aluminum housed 15kV substations for the refriger-

ated container storage area at Centerm container

and break bulk cargo facility, Port of Vancouver,

Canada.

Vanco

uver

Inte

rnati

onal A

irport

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Engineered Solutions forMaterial Handling

3

reliable alternatives for larger horsepower wound rotor

motors.

The solution involves inserting resistance in the rotor cir-

cuit to change the characteristics of the wound rotor motor

to match an application’s load/speed requirements. Synergy

provides these systems for controlled acceleration of many

applications including conveyor systems and rock crushers.

“Over the last several years, our role has expanded dramatically in that we

have become a large-scope end-to-end electrical systems provider,” notes

David Atkinson, Synergy’s Executive Vice President and Director. “We do that

by integrating all three aspects of our business-drive systems, power distribu-

tion, and instrumentation & control.

”We work on large projects in a variety of ways, either directly with the end-

user or the engineering procurement construction management company that

represents the end-user, or with the original equipment manufacturer who in

turn supplies the end-user or the EPCM contractor. Increasingly, once our proj-

ect is successfully completed, we are working directly with end-user customer

in terms of ongoing service, support, and maintenance.”

S O U T H A M E R I C Aynergy has been adding expertise and increasing its role since its first

major project in Chile in 1994 for Minera Escondida Ltda.,

one of the largest sources of copper and one of the most productive

open-pit copper mines in the world, providing 8% of the worlds copper pro-

duction.To move approximately 350 million tonnes of material from the open

pit each year, the mine utilizes the largest crushing and conveying systems in

the industry. Synergy’s first project was the design and supply of 14,000 horse

power in four conveyor drive stations for the Phase III expansion of Escondida’s

operation with Fluor Daniel as the EPC contractor. Synergy’s deliverables—

efficiency, reliability and life-cycle cost-savings-have led to greater opportuni-

ties. Again in 1996, the company was asked to provide solutions for Minera

Escondida’s E1 expansion phase with BHP Engineering as the EPC contractor.

“Synergy was asked to engineer four conveyor drive systems controlling ten

large 1200kW motors,” says Atkinson. “We had already successfully designed

and supplied a number of conveyor drive stations to Escondida’s Phase III

expansion, but this marked the evolution of Synergy from a ‘design and supply’

company to a company recognized for its capability to provide a broader engi-

neering solution.As we began to be recognized as having core competencies

badly needed by our customers, we were asked to participate further and fur-

ther up stream in project scope. Now, we are often asked to write some of the

specifications as part of our engineering deliverable, in addition to providing

the downstream detailed engineering and design, manufacturing, installation

supervision and commissioning—the full-scope role.”

When the mine again expanded capacity by beginning their Phase IV expan-

sion with Bechtel as EPC, the task of providing drives, electrification, and

instrumentation and control was assigned to Synergy. Synergy designed and

supplied the end-to-end package of electrical equipment for the in-pit crusher

and discharge conveyor as well as the overland conveyor system.The project

included building several large E-houses and a master control room, along

with all the necessary PLC and HMI equipment.

Achieving growth through excellence, Synergy continued to increase its

activities at the mine in 2002, engaging in five separate projects. Working

again for Minera Escondida, Synergy conducted the preliminary engineering

for crushing, conveying, and electrification for successive mine expansion proj-

ects known locally as E2, E3, and Norte.

In addition, Synergy supported Minera Escondida’s Oxide operation, replac-

ing fluid coupling conveyor drives with Wound Rotor Induction Motors and

Secondary Resistive Controllers.

“These SRC motor controllers offer many advantages over the Variable

Frequency Drive alternative,” observes Rick Neuman. “SRC solutions are very

cost-effective and can be less than sixty five percent of the cost of a VFD sys-

tem for large horsepower applications, and they have several other advan-

tages. With a VFD, electronics are involved, so it’s not sufficiently robust in

harsh environments, but the SRC is very robust. The SRC does not require an

▲ Two E-houses, master control room, large drive

motors, PLCs, HMI, etc. for in-pit crusher and discharge

conveyor at Minera Escondida’s Phase IV expansion.

S

Min

era

Esc

ondid

a

air-conditioned, climate-controlled environment and does not require

an indoor installation. Many of our SRC installations are located out in

the open in dusty, damp environments; others are located deep inside

tunnels where space limitations make a VFD system problematic, if not

impossible.”

Additional cost savings are gained because on-site electricians can

do the field repair, testing and maintenance rather than bringing in

specially trained technicians with the specialized test equipment

required for VFD repair. As a result, downtime and costs are reduced.

Recommended spare components are kept to a minimum, further reducing the

money invested in the system and improving life-cycle cost. These features of

reliability, maintainability, reduced life-cycle costs and higher system availabili-

ty are important to our customers, and are even more critical to our customers

who are in remote locations.

“We often find that end-users have a VFD system in place when perhaps

they shouldn’t for the specific application. The good news is that replacing

VFDs in these applications pays for itself very quickly.We have customers who

have replaced VFDs with a WRIM/SRC solution, and they’ve achieved payback

in less than a year,” notes David Atkinson. “Our customers believe it is critical

to look at full-life-cycle cost in the evaluation of alternatives.As another exam-

ple, the capital cost of a SRC solution is higher than that of a Liquid Rheostat

solution, but the life-cycle cost the SRC solution is much lower.”

In 2002, with Sandwell as EPC contractor, Synergy engineered the upgrade

of an electrical control system at Minera Escondida in conjunction with

mechanical upgrade for shiploader at the port of Coloso.

“This time, we were involved in the complete chain of material handling

processes that begin in the open pit and ultimately deliver material to the sea-

port,” says Atkinson. “In this instance, our work was at that seaport end with

the electrical and control system, in conjunction with Sandwell’s mechanical

upgrade for the shiploader, which is a conveyoring gantry type system. Instead

of having the conveyor running along the floor of a mine or along the surface

Four large E-houses, 1 x 1200kW

Wound Rotor Induction Motor (WRIM)

and 7 x 2000kW Wound Rotor Induction

Motors (WRIM), PLCs and switchgear for

the overland conveyor system in

Escondida’s Phase IV expansion.

4

▲

of the land, it’s supported high above the ground on a steel structure.The end

of the movable conveyor is suspended hundreds of feet in the air, because it’s

being used to feed processed material into a number of ship hatches.

For Minera Escondida’s subsequent E3 expansion, with BHP Engineering in

the role of EPC, Synergy was contracted to design and supply the electrical and

control equipment for the relocation of two existing in-pit crushing and con-

veying systems. This included the supply of new E-Houses, motors and

Secondary Resistive Controllers complete with PLC hardware and software,

and HMI modifications to integrate into the existing ore distribution system.

The mine’s E3 project was immense, with Synergy’s portion alone encompass-

ing a total connected horsepower of 23,000hp with 59 motors and more than

2,000 cables for a total length of 157 kilometres.

Synergy delivered successfully on that phase and went on to another large-

scale project at the mine in 2004 and 2005 for the Norte expansion with Hatch as

EPC contractor. Synergy’s role in the Norte project was the design and supply of

electrical and control equipment for an in-pit 750kw gyratory crusher, along with

more than seven kilometres of overland and distribution conveyors. In addition,

the company provided four e-houses, the main control room, large drive motors,

Secondary Resistive Controllers, and the PLC hardware and software.

“Norte required a total connected power of 10,000hp with 46 motors and

1,446 cables for a length of over 122 kilometres, along with 919 total instru-

ments,” says Atkinson.

“The scope of the project demonstrates that whatever the assignment, we

have the resources and the capabilities to satisfy the needs of the customer.

The highlight for us in Chile is that over the past 12 years we have been a

selected contractor in virtually every one of Minera Escondida’s major expan-

sion phases—I believe no one else can lay claim to this unique achievement!”

By the end of the 1990s, Synergy’s early success as a supplier of major end-to-

end electrical projects in Chile led to opportunities in Peru. Located 270 km

north of Lima, the Minera Antamina mine is one of the largest copper and

zinc producers in the world.The mine is operated by Compañia Minera Antamina,

owned by BHP Billiton, Noranda Inc.,Teck Cominco Ltd. and Mitsubishi Corp.

Bechtel brought in Synergy to engineer the automation of the coarse ore

crusher, conveyors, and the stacker for the mine site, including complete sys-

tem logic design, PLC programming and HMI design and development.

When the mine went into production, a new port facility was needed to

process the ore concentrate and transfer it to deep-sea vessels. Synergy was

asked to engineer, design and manufacture a complete electrical system,

including control, communications, and power for a 1,600-tph shiploader at

Port Huarmey.

PA C I F I C R I Ms Synergy prospered in South America, the company also began to

expand its geographic reach to the Pacific Rim, introducing its

SRC/WRIM technology to Indonesia’s Grasberg mine, operated

by P.T. Freeport Indonesia Company, a subsidiary of Freeport-

McMoRan Copper & Gold Inc.The Grasberg site, in the easternmost Indonesian

province of Papua, is the world’s largest

single gold deposit and third-largest

copper mine and is further unique in

that it operates at a mountain top ele-

vation above 4,200 metres (13,800 feet).

Initially, Synergy was

requested to engineer

a Wound Rotor 1000hp

crusher and 800hp

Conveyor Secondary

Resistive Controller.

Based on the success of this project, P.T. Freeport challenged Synergy to tack-

le an assignment that was many times larger. Synergy engineered a solution

involving six 600 hp wound rotor induction motors and Secondary Resistive

Controllers for accelerating and jogging three conveyor applications. In 2005,

P.T. Freeport ordered six more motors and three SRCs for the Grasberg mine.

▲ SRCs installed at PT Freeport, Indonesia on the island

of Papua. 4,000 m.a.s.l.; Jog function for maintenance;

dedicated PLC. Wet and dusty environment.

Papua, Indonesia.

Minera

Antamina,

Peru.

5

PT

Fre

eport

Indonesi

a

A

Min

era

Anta

min

a

C A N A D An a very short span of time Synergy has evolved into a global player by

leveraging the competence in problem solving it had demonstrated for its

original end-user customers on its home turf. In an unrivalled track record

of success over the past two decades, Synergy has participated in numerous

projects in the Canadian West, including providing solutions for Teck Cominco

at the Highland Valley copper and molybdenum mine near Kamloops, BC, for

Texada Quarrying Ltd. for both their limestone and aggregate quarries on

Texada Island, and for the Alberta-based Syncrude Canada Ltd., arguably the

world’s largest producer of crude oil from oil sands, as well as for Shell

Canada’s Albian Sands operation.

Back in 1990, Highland Valley Copper became Synergy’s first high

profile Canadian client. Neuman’s young start-up company soon proved it was

up to the task of bringing cost-efficiencies to one of Canada’s largest mining

operations through the design, manufacture and supply of a special 2000 KVA

mobile diesel generator set for moving mobile mining equipment.

“We didn’t engineer their shovel mover, but we were responsible for the

design of the mobile diesel gen set that is used to operate it,” says Neuman.

“There’s a diesel engine in it and it’s running a generator that creates power. It

solved a

problem

and created a real savings in life-cycle costs. Being able to put together this

mobile set according to their specifications and have it work and continue to

work over the years really went a long way toward establishing Synergy as a

world-class solutions provider. It speaks volumes about how we bring greater

efficiencies and cost-savings to our customers.”

The success of the initial project led to a steady stream of work at Highland

Valley, where amongst other projects Synergy was hired to design, manufac-

ture and supply a new overland conveyor drive system with a new improved

PLC control system, switchgear, secondary resistors, contactor cabinets and

three wound rotor motors.

In the mid-90s, Highland Valley Copper called upon Synergy to design and sup-

ply nine 800hp frequency drives systems, including the VFDs, transformers, motors

and PLC control systems for a new tailings pumping station.“We don’t always

implement an SRC solution,” Neuman was careful to point out.“In our engineer-

ing judgment, we want to provide the best solution for the client’s application,

and sometimes something other than an SRC is the appropriate solution.”

In 2001, acting on a recommendation from Synergy, Highland Valley Copper

decided to replace six existing VFD pump drives with six 1250hp Wound Rotor

Motor Slurry Pump Drives.

“Everybody was taking a big step forward and a fair amount of risk to see

whether this would work or not,” Neuman recalls. “This was our first opportu-

nity to apply SRC/WRIM solutions to a pumping application.The fact was that

the VFD pump drives were costing too much to run. One of the major issues is

electronics. In contrast, our SRC solution has no power electronics.

“The SRC is very robust and highly efficient, even with minimal speed con-

trol. It’s an engineered system, meaning we create a unique design for each

application, rather than selecting one off the rack. Another key issue is life-

cycle costs. The SRC/WRIM solution is maintainable by the end-user and

requires extremely low maintenance.We have systems that are operating in

▲ New electrical house installed at Highland Valley

Copper as an upgrade to their 138kV substation.

Overland conveyor drive system

for Highland Valley Copper, includ-

ing PLC control system, switchgear,

secondary resistors, contactor

cabinets and three wound rotor

motors.

▲

▲ SRC solutions for crushing and

conveying applications at Syncrude Canada.

6

I

Hig

hla

nd

Valley

Copper

Indonesia at high altitudes and humidity, and deep within tunnels, that haven’t

even had to have the cabinets opened for a number of years.”

Another high-profile client for Synergy in the Canadian West is Texada

Quarrying Ltd. The original quarrying operation on Texada Island was

built in 1973 to provide crushed limestone to the cement, agricultural and

chemical industries. Operated by Texada Quarrying Ltd. in a joint-venture with

Lafarge Canada Construction Materials Group, the plant underwent a major

rebuild in 2000 to increase production, storage capacity, and flexibility. The

crushing and materials transport equipment was replaced in the limestone

quarrying operation including updated and new crushers, a new screen plant,

a dozen vibratory feeders, and a total of 15 conveyors.

At the other end of the property and totally independent from the limestone

quarry, a portable aggregate plant was installed to supply the construction

industry with a wide variety of products ranging from asphalt aggregate to

crushed rock. Installed equipment included primary and secondary crushers,

screen decks and a number of conveyors and stackers.

Synergy Engineering Ltd. was contracted to provide the total electrical pack-

ages for both plants, including engineering the design of the power distribu-

tion system from 12.47 KV downwards, the design of plant automation includ-

ing PLC & HMI programming, the design and supply of multiple control rooms,

prefabricated electrical rooms, substations, a 4160-volt motor control centre

utilizing a Synergy wound rotor motor secondary resistance controller, plant

lighting, fibre optic communications, PLC cabinets, field instrumentation

devices and HMI control systems, as well as the provision of installation super-

vision and commissioning.

Repeat business with customers such as Texada Quarrying and Teck Cominco

has continued over the years and so has Synergy’s long-term involvement with

Syncrude Canada Ltd., the biggest player in the Alberta oil sands.

Synergy’s involvement in the oil sands began in 1993 when Rick Neuman

conducted an engineering analysis of existing starting resistors and accelera-

tion control schemes for Syncrude. He then designed a new improved system

involving supply, manufacture and installation of a new drive station, control-

ling four 1250 hp Wound Rotor Induction Motors.

Later on, Synergy was asked to design and supply Syncrude with custom

manufactured Resistors and Rotor Contactor Cabinets for 1250hp and

900hp wound rotor motors for conveying and crushing applications.

Synergy soon broadened its scope of offerings in the oil sands to

include switchgear, control philosophy, and functional specifications in

addition to its unique deliverables in SRC solutions.

At the Aurora II phase of Syncrude’s oil sands operation, Synergy was

asked to design and supply wound rotor motor resistor equipment for a

Surge Bin Feed Conveyor and Mix Box Feed Conveyor. On its next

Syncrude project, Synergy engineered a retrofit of five wound rotor

motors and SRCs for conveyor applications with specially designed automatic

load-sharing function for oil sands.

“This added feature gives the customer more bang for his buck,” says David

Atkinson. “It enables customers to have more flexibility.They can tweak things

in the future to add functionality.There might be a change of use for a particu-

lar conveyor, so they’re prepared for that, and they don’t have the job done all

over again.That makes it easier for them to respond to the changing configu-

ration issues in the future.”

In the Canadian oil sands, business is booming, and Synergy is engaged in

providing expertise and full-scale solutions to other mining operations now

active in the area, including Albian Sands, owned by Shell

Canada. Synergy has provided three 2600kW conveyor Secondary Resistive

Controller drive packages and three single 800kW conveyor drive packages for

their Albian Sands operation, and is leading the way in providing reliable, cost-

effective solutions in this region and around the world.

“One of the greatest strengths of the SRC product is the technological and

operating life expectancy,” says Rick Neuman. “In most cases the technologi-

cal life of a Variable Frequency Drive is five years, and the reliable operating life

is ten to twelve years.With the SRC drive, the technological life is estimated to

be in the range of 20 years, and the operating life in excess of 20 years.

“The Secondary Resistive Control solution that Synergy provides is designed

with the basic standards of good engineering, which creates a system that is

cost-effective, efficient, maintainable and, above all, reliable.” ■

▲ Total electrical

packages, both for

the replacement of

the limestone

crushing and materials handling system, and for the new

portable aggregate plant at Texada Quarrying Ltd., Texada

Island, British Columbia, Canada.

7

Syncr

ude C

anada

Shell C

anada

Texada Q

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E N G I N E E R E D S O L U T I O N S F O R M A T E R I A L H A N D L I N G

VANCOUVER • EDMONTON • SANTIAGO, CHILE

www.synergy-eng.com

E - M A I L :

office@synergy-eng.com