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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
S
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
uarr
yin
g
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