Complexity in integration high voltage and ventilation systems Warwick Young

1. APPIN MINE HIGH VOLTAGE AND VENTILATION
ARRANGEMENTS
COMPLEXITY IN INTEGRATION
• NOVEMBER 2017

2. SLIDE 2
•INTRODUCTION
•History of the individual mines
•High Voltage supplies
•Ventilation arrangements
•Ventilation and power interlocking
•Organisational structure to support the High Voltage
and Ventilation infrastructure.

3. •ILLAWARRA COAL
Bulli
Wollongong
Sydney 50kms

4. SEPTEMBER 2017 APPIN RESTART PROJECT SLIDE 4
•SURFACE INFRASTRUCTURE

5. • Appin Mine – commenced 1962
• West Cliff Mine – commenced 1976 (Originally Kembla Coal and Coke Pty Ltd).
Purchased by Illawarra Coal in late 1997)
Tower Mine – commenced 1980
• Appin Mine:
• Dual drift configuration with Belt Drift and Single Rope drift winder (dolly car)
• 2 x Vertical Shafts for Remote Fan site with Fans capacity of 276m3/sec.
• Remote Gas drainage plant with capability of 5000l/s.
• 2 Main High Voltage Switchyards. 66KV/6.6KV (1x 10MVA + 3 X 5 MVA )
• Gas driven Electrical Generation plant with capacity of 40MW
• SINGLE MINES INFRASTRUCTURE
CONFIGURATION

6. • West Cliff Mine:
• M&M Drift Winder Single rope winder (Dolly Car)
• Vertical Shaft (500mts) with Bulk Coal winder(760 TPH)
• Vertical shaft with Auxiliary winch
• 2 Main Fans on Site 11KV 800KW also utilised 5 underground Booster Fans. (Total
installed ventilation power of 6.1MW).
• Gas Drainage plant with capacity of 5000 l/s
• Gas Generation Plant 6 MW Capacity.(Utilising Vent Air Methane)
• 2 Main switchyards 66KV/11 KV (2 x 12.5 MVA) (2x 12.5MVA)
SEPTEMBER 2017 APPIN RESTART PROJECT SLIDE 6
•SINGLE MINE CONFIGURATION

7. • Tower Mine
• 2 x Vertical Shafts with M&M Frictional Winder and Bulk Coal Winder
• 2 x 800 KW Ventilation Fans
• Second remote Main fan site (Vent Shaft 3)
• Gas Drainage Plant with capacity of 5000l/s
• 2 Main Switchyard 66KV/11KV ( 2 x 5.4MVA) + ( 1 x 4.5MVA)
• Gas generation Plant with capacity of 40MW
SEPTEMBER 2017 APPIN RESTART PROJECT SLIDE 7
•SINGLE MINE CONFIGURATION

8. •APPIN MINE
WEST PORTAL
NORTH PORTAL
EAST PORTAL

9. • Appin Mine joined with Tower Mine prior to the commencement of the Douglas project . This allowed
Appin Mine to extend into the Tower lease and continue to maintain longwall production and coal
extraction via Appin Portal. The Douglas project started in the early 2000.
• At this time Tower Main Fans and BCW were decommissioned. M&M Winder and the Gas extraction
plant continued to operate.
• A new High Voltage switchyard ( 66KV/11KV) was built with 2 x vertical bore holes. This was to allow
maintainability of adequate Electrical fault levels for Appin development and longwall operations.
• AREA 9 project was born in mid 2012: $1Billion Project
• The scope of the project was to create a new mining domain and sustain the production forecasts which
were obtained from Appin Mine (Tower) and West Cliff longwalls.
• There was a requirement for 2 coal clearance corridors hence a connection from West Cliff Area 5 into
Area 7 of Appin to maintain coal stream thru the West Cliff BCW and the current Appin Coal stream from
the new Area 9 to Appin Drift belt.
• Due to the mine workings now moving further away from Main Fan Ventilation the project designed and
built a new vertical shaft with 3 high flow mixed (axial / centrifugal) fans (Vent Shaft 6). This site included
Main High Voltage switchyard, Communications equipment, Site drop holes, compressed air supplies
and Tube Bundle Gas Monitoring equipment. Once this was commissioned and operational VS3 Main
Fans at Appin were returned to Down Cast.
SEPTEMBER 2017 APPIN RESTART PROJECT SLIDE 9
•FORMATION OF APPIN MINE THROUGH
MAJOR PROJECT DELIVERY

10. •APPIN MINE CURRENT OPERATIONAL
CONFIGURATION
The mine has:
• 8 Surface Main ventilation fans.
• Appin East 3 (280m3/s @ 5.4kpa)
• Appin North 2 (1 Operating) 253m3/s @ 2.4kpa
• VS6 3 . (2 Operating) 625m3/s @ 8.5kpa
• 1 Underground Booster Fan (146 m3/s @ 2.8kpa)
• 5 Winders –
• Appin East M&M Drift
• Appin West M& M Shaft
• Appin North M&M Drift
• Appin North Bulk Coal Winder
• Appin North Auxiliary Shaft Winder.
• 9 Surface to Seam power cables – 11kV and 6.6kV 4 via bore hole and 5 via vertical
down cast shafts
• 2 Conveyor streams consisting of ~20 conveyors (2 MW VVVF, TPKL and 1 3MW Slip
Ring Induction / Liquid Resistance Starter)
• 2 gas drainage plants. (Appin West 10000l/s + Appin East 10000l/s)
The mine is configured to operate with 2 operating longwalls and 6 development
panels. Currently reduced to operate with 1 longwall and 1 development unit.

11. •HIGH VOLTAGE SUPPLIES

12. •APPIN EAST 66/6.6KV SUBSTATION
• 66 / 6.6kV Supply
• 1 x 10 MVA Transformer
Appin East Pit Top Substation
circa 1960

13. MARCH 18 GAS DRAINAGE SYSTEM UPGRADE - PHASE 1 SLIDE 13
•APPIN EAST 66/6.6 KV FAN SITE SUBSTATION
3 x 5 MVA 66/6.6 KV Tx
• Fed via EDL Power
station
• Ability to “island” the
supply for network
provider outage.
• Ability to “black start”
from GDP supply
Appin East vent Site
Substation circa 1960

14. •APPIN WEST 66/6.6KV SUBSTATION
• 66/6.6kV Supply
• 2 x 5.4 MVA TX’s
• Fed via EDL Power station
• Ability to “island” the supply for
network provider outage.
• Ability to “black start” from GDP
supply
Appin West Substation
circa 1980
EDL Generation Plant

15. •APPIN NORTH SUBSTATIONS
• 2 x 2 x 12.5MVA transformers
• 66/11kV Supply
• Internal 66kV supply on mine lease
Appin North Main Substation
circa 1975
Brennans Creek Dam Substation
circa 2008

16. MARCH 18 GAS DRAINAGE SYSTEM UPGRADE - PHASE 1 SLIDE 16
•DOUGLAS PARK NORTH SUBSTATION
• 2 x 12.5MVA transformers
• 66/11kV Supply
• Augmentation through Feeds 66kV
Supply to VS6 via under bore of
Sydney to Canberra Freeway and
southern railway
Douglas Park North Substation
circa 2009

17. MARCH 18 GAS DRAINAGE SYSTEM UPGRADE - PHASE 1 SLIDE 17
•VENT SHAFT 6
Vent Shaft Six Substation circa
2015
• 3 x 6.5MVA transformers
• 66kV/3.3kV/415V Supply
• Supplies 3 x 4.3MW
Surface fans
Appin East Pit Top Substation circa 1960

18. •Superintendent Automation and Control for Appin Mine
• Electrical Trade
• Electrical Diploma
• Degree in computer Engineering.
• Certified TUF Functional Safety Engineer.
• Primarily Steel Industry and 6 years with Illawarra Coal.
MARCH 18 GAS DRAINAGE SYSTEM UPGRADE - PHASE 1 SLIDE 18
•BEN PATON

19. •VENTILATION ARRANGEMENTS
Fans
• 2 ventilation districts
separated by triple
doors and coffin seal
• VS6: 3 x 3.3kV 4.3MW
VSD Fans (2 duty, 1
standby)
• VS2: 3 x 900KW 6.6kV
DOL Fans
• VS1: 2 x 850KW 11kV
DOL Fans
• North Mains BF: 1 x
1.5MW 11kV DOL Fan
Appin North
Ventilation District
Intertripping
• Failure of VS6 or VS2
trips UG power to
East/West
• Failure of VS1 trips UG
power to North
• Failure of Booster Fan
trips power inbye of the
Booster Fan
Appin East/West
Ventilation District
Booster Fan
VS2
VS1
Doors & Seal

20. MARCH 18 GAS DRAINAGE SYSTEM UPGRADE - PHASE 1 SLIDE 20
•SIL RATED INTERLOCKING SYSTEM
Process:
• Failure Modes and Effects Analysis (FMEA) – multiple iterations
• Layer of Protection Analysis (LOPA) – risk based design methodology
• Defined SIL2 Requirement (Safety Requirements Specification)
• Conceptual (internal) and detailed (external) hardware design
• Software Design (external)
• Installation, testing & commissioning – due to put into service early Dec ’17
System:
• Network of thirteen (13) GuardLogix Safety PLCs connected on dedicated
redundant fibre optic ring
• GuardLogix primarily used for SIL rated communications
• Monitors input signals at fans (triple redundant collar pressure transmitters) and
trips mine feeders and UG circuit breakers
• Required interfacing wiring to fans and feeders while current system in use

21. MARCH 18 GAS DRAINAGE SYSTEM UPGRADE - PHASE 1 SLIDE 21
•SIL RATED INTERLOCKING SYSTEM

22. • Currently
• 1 statutory Manager for each discipline (Electrical / Mechanical and Mining)
• Each statutory manager has Technical qualified engineers to assist 1 each in the Electrical and
Mechanical area. Mining area is similar but has additional resources to cover for Ventilation and
hence VO officers to assist.
• A new position of Manager Surface infrastructure has been created.
• A surface Superintendent position exists.
• Appin West and VS6 has an Electrical and Mechanical technical engineer for the surface
infrastructure. (Coordinators)
• Appin East and Appin North has an Electrical and Mechanical technical engineer for the surface
infrastructure. (Coordinators)
• Each Portal (Appin North, East and West) has 24/7 rostered coverage for Electrical tradesman
and Day and Afternoon coverage of Mechanical tradesman. Remote Fan sites are covered with
trades from either East and West portals.
MARCH 18 GAS DRAINAGE SYSTEM UPGRADE - PHASE 1 SLIDE 22
•ORG STRUCTURE TO SUPPORT HIGH
VOLTAGE
Appin East Pit Top Substation circa 1960

23. • Special thanks to
• Dave Byrne Manager Electrical Engineering support (2IC)
• Ryan Young Mine Services Electrical coordinator.
• Completing a full review of all Principle Hazard management plans.
• Electrical Control Plan for Appin
• Review of all supporting Standards of Engineering practice.
⎯ Review of content
⎯ Review of legal compliance to legislation.
• Document review to support Departmental TAP inclusive of site interviews and
inspections. (Fire and Explosion)
• Pulling the content together for this presentation.
MARCH 18 SLIDE 23
•THANKYOU