Voltage Dip

-
_______________________________________________________________________
Kabo Ngwanaamotho [email protected]

Kabo NGWANAAMOTHO
MEng Hons Project Report Phase 2
HSP 1943

Transient Analysis of Voltage Dips

January 2006

Transient Analysis of Voltage Dips - i --
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MEng Project Mission Statement
Background:
As a mine, one of the problems that have not been resolved is the performance of motor
drives under different power quality conditions which are also influenced by incremental
weather, faults on the local and external network to the mine.

Project Definition:
This project will focus on carrying a transient analysis of voltage dips with a view to
understanding how they manifest themselves on a network and how to mitigate against
voltage dips on transmission and distribution systems. This will also entail the analysis
and improvement of current methodologies that are used in mitigating against power
quality.

Aims:
Identify causes of voltage dips in the Mine
Investigate possible solutions to the problem

Location:
Debswana Diamond Mining Company, Jwaneng Mine, Botswana. The town of Jwaneng
is located about 180km south of the capital, Gaborone.

Transient Analysis of Voltage Dips - ii --
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Abstract
Voltage dips are increasingly becoming a major power quality problem for Jwaneng
Mine. A dip lasting a few milliseconds can culminate into interruption of critical and
essential processes that could last several hours and the restart process of a plant after a
voltage dip can be very tedious leading to a substantial revenue loss.

This report is Phase 2 of a 2 part research into the causes, effects, characteristics and
ways to mitigate against voltage. Phase 1 report addressed mostly the first three of the
aforementioned parts whereas this report concentrates on solutions.

The first chapters address how well voltage dips are being documented within the entire
mine and goes on to research about the Red Area Plant which was not covered by Phase 1
report. The other chapters analyze solutions in terms of reducing occurrence of voltage
dips or compensating by means of several energy storage systems or smoothing out the
supply voltage using switches or a reactive VAr compensator. Last but not least
recommendations in terms of general power mitigation are discussed to optimize quality
of supply and a method of recording of dips is suggested.

Finally this report reviews the objectives of this research, concludes and specifies what
future work may need to be carried out.

Transient Analysis of Voltage Dips - iii --
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Declaration of Originality

I declare that this thesis is my original work except where stated

Kabo Ngwanaamotho January 2007

Transient Analysis of Voltage Dips - iv --
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Company Background Jwaneng Diamond Mine
Jwaneng mine is under Debswana Diamond Mining Company. Debswana is a company
in which the Botswana Government and the De Beers Consolidated Mines Ltd hold a
50% share each with a total of four mines in Botswana at Jwaneng, Orapa, Letlhakane
and Damtshaa. Jwaneng Mine alone employs more than 2289 people of which 296 are
Engineers of various disciplines.
1
Jwaneng mine started its operations in 1978. A new
contract that will run for the next 25 years has just been signed this year (2006).
2

In 2005, the mine treated 10 006 752 tons of kimberlite ore, yielding a record 15 618 155
carats.
1 above
for the year Debswana had group total revenue of BWP15.8 billion.

Debswana is a key player in the national economy of Botswana, producing in excess of
70% of Botswana's export earnings, 30% of Gross Domestic Product (GDP) and 50% of
government revenue.

Mining at Jwaneng mine is by open pit. The mining process can be divided into 5
sections;

1. The Mine Pit - Kimberlite is blasted, hauled and crushed to a size of particles less
than 150mm in diameter. This ore is then conveyed to the primary stockpile.
2. MTP - The ore to the MTP is drawn from the primary stockpile and conveyed to
the scrubber feed bins. This ore is then scrubbed and screened. Less than 25mm
ore goes to the feed preparation stockpile. Greater than 25mm ore goes to the
secondary stockpile and is then crushed further. From the feed preparation
stockpile the ore goes to the DMS. Here the ore is separated according to density,
while diamond rich material, being denser sinks in a FeSi medium, and the non-
diamond rich material floats.

1
http://www.jwaneng.debswanaintranet.com/home/fraStart.asp - accessed 7/31/2006 7:40 AM
2
DeBeers Group Annual Review
Transient Analysis of Voltage Dips - v --
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3. Recrush Plant - The tailings from the MTP DMS are crushed to less than 8mm
and then scrubbed and screened and then go to the Recrush DMS.
4. Final Recovery (Red Area) - Ore from the MTP and Recrush DMS is
transported to the Aquarium where diamonds are recovered from the concentrate.
5. Tailings - The tailings from the Recrush DMS in the size range of less than
25mm and more than 1mm is finally conveyed through the Recrush tailings
conveyor system to the tailings dumps. This ore is used to facilitate compact
ability and stability of the dumps.

Jwaneng Mines Electrical Reticulation

There are two 132kV incomer O/H lines from the BPC substation at Thamaga [Appendix
A6 & A7 Report Phase 1] feeding Jwaneng mine. The average overall power demand for
the mine is about 33.9MW. Two 20MVA 132/6.6 kV transformers (T1 and T2) supply
MTP, Mining Offices and the workshops closest to the switchyard, another two 25MVA
132/33 kV transformers (T3 and T4 (600A on primary)) are for Well fields (50km), Re-
crush No1 (4km), and Village (township) 1 & 2 on Busbar A - Pit O/H line (7.34km), Re-
crush No2 (4km) on Busbar B.

The mine has two standby diesel generators rated 1.725MW and 2.6MW which generate
at 6.6kV and supply Busbar A with 33kV via a 5MVA transformer in case of an outage.
In the standby generator housing there is a 280kW Auxiliary generator which
automatically starts if the supply from BPC goes off. The standby diesel generators are
manually started.

Transient Analysis of Voltage Dips - vi --
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Acknowledgements
I would like to convey my gratitude to Kenny Sinyinza Section Engineer electrical
services who my industrial supervisor at Jwaneng Mine for his help in pointing me
towards the right direction in research for this project.

I would also like to thank all the personnel at MTP, RP, Red Area Plant and the Electrical
Workshops in Jwaneng Mine for their continued support and invaluable comments for
this report.

I thank Disang Mongatane at MTP, Isang Gaolebale and Simon Nyirongo at Re-crush
Jwaneng for the daily production reports at their respective plants and their comments for
economic impact of voltage dip for this report. I also thank Nonofo Kebaitse in the
Diamond Value Management for files to assess revenue losses due to voltage dips.

I am grateful to the help of Otto Keitumetse, Section Engineer MTP, Puso Mooketsi,
Section Engineer at the Red Area Plant, Bobotho Ratsoma, Section Engineer at Recrush,
Josiah Keitshokile Assistant Plant Superintendent at the Red Area Plant.

I would also like to convey my appreciation for answering my questionnaires to Phana
Matale and Patrick Wakatama at EM15, Jonathan Sesinyi at ET13, Victor Bontsi and
Bojosi Tonkope at the Red Area Plant workshop, T.T Badisang, BAHF manager at the
Red Area plant and Calvin at the Recrush workshop for the daily shift reports

The editorial comments from Kelebonye Leduledi and Segale Mangope on the first phase
of this research are highly appreciated.

My gratitude is also due to Mrs. Same Makuku, protection engineer Operations and
Transmission at BPC Gaborone , Mr. Wilfred Shereni, metering engineer at BPC
Gaborone and Mr. Chris Ngulube and all personnel at NCC for shedding a light on
Transient Analysis of Voltage Dips - vii --
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structure of Botswanas transmission network and allowing me full access to their records
and reports.

I would also like to thank my project supervisor Dr Ewen Macpherson and Dr David
Renshaw at the University of Edinburgh, UK for ensuring that this project is up to
professional standard.

Transient Analysis of Voltage Dips - viii --
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CONTENTS-----------------------------------------------------------------------------------PAGE
MENG PROJECT MISSION STATEMENT............................................................................................. I
ABSTRACT................................................................................................................................................. II
DECLARATION OF ORIGINALITY..................................................................................................... III
COMPANY BACKGROUND JWANENG DIAMOND MINE.......................................................... IV
ACKNOWLEDGEMENTS....................................................................................................................... VI
LIST OF SYMBOLS AND ABBREVIATIONS...................................................................................... XI
GLOSSARY OF TERMS ....................................................................................................................... XIV
PROJECT PLANNING............................................................................................................................XV

1 INTRODUCTION............................................................................................................................... 1
1.1 PROJECT OBJECTIVES & SCOPE.................................................................................................... 1
1.2 BACKGROUND INFORMATION....................................................................................................... 1
1.2.1 Power Quality Issues .............................................................................................................. 2
1.2.2 Definition - Voltage Dip ......................................................................................................... 3
1.2.3 Voltage Dip Types .................................................................................................................. 4
1.2.4 Selected Literature Review..................................................................................................... 6
1.3 PROJECT METHODOLOGY............................................................................................................. 7
1.4 THESIS OUTLINE .......................................................................................................................... 8
2 CURRENT METHODS OF RECORDING OF DIPS................................................................... 11
2.1 BALANCED SCORE CARD (USE OF POWER QUALITY METERS).................................................. 11
2.2 POWER DIP RECORD SHEET ....................................................................................................... 12
2.3 CCR........................................................................................................................................... 12
2.4 ELECTRICAL WORKSHOP............................................................................................................ 13
2.5 BPC........................................................................................................................................... 13
2.6 RED AREA PLANT ...................................................................................................................... 13
2.6.1 Treatment.............................................................................................................................. 14
2.6.2 External to the Red Area Plant ............................................................................................. 14
2.6.3 Security................................................................................................................................. 14
3 EFFECTS OF POWER DIPS IN THE RED AREA...................................................................... 15
3.1 SECURITY................................................................................................................................... 15
3.1.1 Magnetic Locks..................................................................................................................... 15
3.1.2 Central Command Centre..................................................................................................... 15
3.1.3 Back-Up System.................................................................................................................... 16
3.2 ACID HANDLING (BAHF) .......................................................................................................... 16
3.2.1 Scrubber ............................................................................................................................... 16
3.2.2 Neutralization Process.......................................................................................................... 17
3.2.3 Compressor........................................................................................................................... 17
3.3 GENERAL PROCESS..................................................................................................................... 17
3.3.1 Pneumo Blower (Drier System) ............................................................................................ 18
3.3.2 Feed Preparation Conveyors................................................................................................ 18
3.3.3 SICON................................................................................................................................... 18
3.3.4 Perm Rolls ............................................................................................................................ 19
3.4 INTERNET SERVER DOWNTIME................................................................................................... 19
3.5 AIR CONDITIONING.................................................................................................................... 19
4 ECONOMIC EVALUATION (LOSSES DUE TO VOLTAGE DIPS) ........................................ 20
Transient Analysis of Voltage Dips - ix --
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4.1 LOSSES DUE TO BAD POWER QUALITY....................................................................................... 20
4.2 PRODUCTION DELAY (HEAD FEED DELAYS) .............................................................................. 21
4.3 FESI LOSSES............................................................................................................................... 23
4.4 SECURITY BREACH..................................................................................................................... 23
5 SUPPLY UTILITY CONDITIONS................................................................................................. 24
5.1 STIPULATION.............................................................................................................................. 24
5.2 POWER QUALITY SPECIFICATIONS ............................................................................................. 24
5.2.1 Voltage & Frequency............................................................................................................ 24
5.2.2 Harmonics ............................................................................................................................ 25
5.3 PROPOSED 220KV TRANSMISSION LINE..................................................................................... 26
6 CRITICAL LOADS.......................................................................................................................... 27
6.1 RED AREA.................................................................................................................................. 27
6.2 MAIN TREATMENT PLANT.......................................................................................................... 28
6.3 RE-CRUSH PLANT....................................................................................................................... 28
6.4 SERVICES ................................................................................................................................... 29
6.5 OPEN PIT.................................................................................................................................... 29
7 REDUCING OCCURRENCE OF DIPS......................................................................................... 30
7.1 POWER QUALITY METERING...................................................................................................... 30
7.2 PROTECTION & DISCRIMINATION............................................................................................... 30
7.3 SIMULATE BAD QUALITY POWER .............................................................................................. 31
7.4 BALANCED NETWORK & HARMONICS ....................................................................................... 32
7.5 POWER FACTOR CORRECTION.................................................................................................... 35
7.6 SOFT STARTING LARGE INDUCTION MOTORS ............................................................................ 36
7.7 EARTHING.................................................................................................................................. 36
7.7.1 Neutral Earthing Resistor..................................................................................................... 37
7.7.2 Neutral Earthing Compensator ............................................................................................ 38
7.8 REDUCE EQUIPMENT SENSITIVITY ............................................................................................. 39
8 COMPENSATE MISSING VOLTAGE......................................................................................... 40
8.1 BESS - BATTERY ENERGY STORAGE SYSTEM ........................................................................... 40
8.1.1 Cost Analysis ........................................................................................................................ 41
8.1.2 Technical Analysis................................................................................................................ 41
8.1.3 Connection............................................................................................................................ 42
8.2 SMES- SUPERCONDUCTING MAGNETIC ENERGY STORAGE SYSTEM......................................... 42
8.2.1 Cost Analysis ........................................................................................................................ 43
8.2.3 Connection............................................................................................................................ 44
8.3 UPS ........................................................................................................................................... 45
8.3.1 Principle of Operation.......................................................................................................... 46
8.3.2 Case Study - Synchrotron Radiation Source......................................................................... 46
8.3.3 Case Study - Uses in the mine............................................................................................... 47
8.4 FLYWHEEL ENERGY STORAGE ................................................................................................... 49
8.4.1 Cost Analysis ........................................................................................................................ 50
8.5 POWER CONVERSION SYSTEM.................................................................................................... 51
8.5.1 Proposed System................................................................................................................... 51
8.5.2 Cost of the PCS..................................................................................................................... 52
8.6 CASE STUDY COST BREAKDOWN OF SMES AND BES ............................................................ 52
9 SMOOTHING OUT VOLTAGE PROFILE.................................................................................. 54
9.1 SSTS - THE SOLID STATE TRANSFER SWITCH............................................................................ 54
9.1.1 The Hybrid SSTS................................................................................................................... 54
9.1.2 Connection............................................................................................................................ 55
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9.2 SETC - STATIC ELECTRONIC TAP CHANGER.............................................................................. 57
9.3 SVC - STATIC VAR COMPENSATOR........................................................................................... 58
9.3.1 Principle of Operation of the SVC........................................................................................ 58
9.3.3 Connection............................................................................................................................ 61
10 GENERAL POWER QUALITY MITIGATION........................................................................... 63
10.1 FERRANTI EFFECTS .................................................................................................................... 63
10.2 BLACKOUTS (INTERRUPTIONS)................................................................................................... 63
10.3 SURGES (SWELLS) ...................................................................................................................... 64
10.4 OVER VOLTAGES & UNDER VOLTAGES....................................................................................... 64
10.5 HARMONICS & INTERHARMONICS.............................................................................................. 64
10.6 NOTCHES.................................................................................................................................... 64
10.7 VOLTAGE FLUCTUATIONS (FLICKER) ......................................................................................... 65
10.8 RECORDING & REPORTING OF POWER DIPS (PROPOSED)........................................................... 65
10.8.1 Procedure ........................................................................................................................ 65
10.8.2 Follow up Action/ Feedback ............................................................................................ 66
10.8.3 Responsibilities ................................................................................................................ 66
11 DISCUSSION.................................................................................................................................... 68
11.1 PROJECT OBJECTIVE REVIEW..................................................................................................... 68
11.2 CONCLUSIONS............................................................................................................................ 68
11.3 FUTURE WORK ........................................................................................................................... 70
REFERENCES ........................................................................................................................................... 71

APPENDIX A1 EFFECTS OF CAPACITANCE................................................................................. 75
APPENDIX A2 EFFECTS OF LOAD................................................................................................... 76
APPENDIX A3 - DELAYS DUE TO DIPS 2005.................................................................................. 77
APPENDIX A4 - UTILITIES FAILURES - RED AREA....................................................................... 78
APPENDIX A5 CARATS STATISTICS & REAGENT CONSUMPTION....................................... 80
APPENDIX A6 SAG GENERATOR COSTS @ PSL.......................................................................... 81
APPENDIX A7 EARTHING FOR DIFFERENT SECTIONS............................................................ 82
APPENDIX A8 FLYWHEEL VS. BATTERY ENERGY .................................................................... 85
APPENDIX A9 - POWER DIP RECORD SHEET................................................................................. 86
APPENDIX A10 - MAXIMUM POWER DEMAND.............................................................................. 88

Transient Analysis of Voltage Dips - xi --
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List of Symbols and Abbreviations
A Amperes
AC (ac) Alternating Current
ARC Automatic Re-Closer
AVR Automatic Voltage Regulator
BAHF Bulk Acid Handling Facility
BPC Botswana Power Corporation
BSP Bulk Sampling Plant
BWP Botswana Pula (Botswana Currency BWP 1 = 100 thebe)
CARP Completely Automated Recovery Plant
CB Circuit Breaker
CBEMA Computer and Business Equipment Manufacturers Association
CCR Central Control Room
CHF- Swiss Francs (Switzerland Currency)
CT Current Transformer
DB Distribution Board
DC (dc) Direct Current
DPI Dip Proofing Inverter
DVR Dynamic Voltage Restorer
ES Energy Storage
Eskom South African Electricity Supply Utility
FeSi Ferro Silicon
FISH Fully Automated Sort House
FLC Full Load Current
FLT Full Load Torque
GTO Gate Turn off Thyristor
HV - High Voltage
3
A voltage normally exceeding 650V
Hz Hertz

3
[CAP. 74:01 S.I, Botswana Power Corporation (Electricity) Bye-Laws under section 28, 21
st
December
1979
Transient Analysis of Voltage Dips - xii --
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IDMT Inverse Definite Minimum Time
IEC: International Electro technical Commission
IGBT Integrated Gate Bipolar junction Transistor
IPDB- Interconnected Power Distribution Board
ITIC Information Technology Industry Council
kV kilo Volts
kVA kilo Volts Amps
kW kilo Watts
LTC Load Tap Changer
LV Low Voltage
3 above
- A voltage not exceeding 250V
MCB Main Circuit Breaker
ms milli seconds
MTP Main Treatment Plant
MV Medium Voltage
3 above
A voltage exceeding 250V but less than 650V
MVA Mega Volts Amps
MW Mega Watt (1000 000 W)
MWh Mega Watt hour
NCC National Control Centre
O/H Over Head
P Real Power
p.f Power Factor
p.u per unit
PC Personal Computer Microsoft Windows based
PCC Point of Common Coupling
PCCIE - Power Conditioning and Continuation Interfacing Equipment
PCS Power Conversion System
PLC Programmable Logic Control
PS Parallel Switch
PSM Plug Setting Multiplier
PSU Power supply Unit
RMS (rms) Root Mean Square
Transient Analysis of Voltage Dips - xiii --
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RP Recrush Plant
RPM (rpm) revolutions per minute
SC Starting Current
SCADA Supervisory Control and Data Acquisition
SICON Conveyor Belt (manufacturers trade name)
Sqrt(X) Square root of the number X
SVC Static Var Compensator
TD Time Delay
TH Thyristor Switch
TSM Time Setting Multiple
UPS Uninterruptible Power Supply
US$ - United States Dollar (US Currency)
V Volts
VAr Volts Amps reactive
VDC Voltage Dip Compensator (Series Voltage Restorer SVR)
VSDs Variable Speed Drives
VT Voltage Transformer
Z Impedance
ZAR South African Rand (South African Currency ZAR 1 = 100 cents)
C Degrees Celsius
Phase
W White Phase
B Blue Phase
R Red Phase
1 or S Single Phase
3 Three phase
Transient Analysis of Voltage Dips - xiv --
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Glossary of Terms
Opportunistic costs: Apparent financial losses due to production downtime.

Critical Process: Essential processes that cannot be started up in a reasonable time
before a set automatic discontinuation due to a power dip

Essential Process: A process that is required to maintain a plant

Busbar: any electrical conductor that makes a common connection between several
circuits

Autotransformer: A transformer that has several taps that are designed to connect
automatically depending on a set requirement

Red Area (Aquarium): The high security plant at Jwaneng Mine where final recovery of
diamonds takes place.

Concentrate: Material that contains diamond bearing rocks

Cycle: Time taken to complete one full sine wave of the alternating current supply for
BPC supply with a frequency of 50Hz this is 20ms

Transient Analysis of Voltage Dips - xv --
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Project Planning
This project was planned as shown in the Gantt chart below. It should however be noted
that most of the tasks were dependent on the cooperation of various mine personnel and
as such the times shown were not strictly adhered to and furthermore most of the tasks
were carried out simultaneously.

Phase 1 of this project involved establishing what the problem is voltage dips. A report
was given out on the 15
th
of August 2006.

The following Gantt chart shows planning of work for Phase 2 of the research on voltage
dips which is mainly concerned with offering recommendations to the mine.
Transient Analysis of Voltage Dips - xvi --
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Transient Analysis of Voltage Dips - 1 --
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1 Introduction
This report is phase 2 of a two part report on the research of voltage dips at Jwaneng
mine in order to suggest ways in which to mitigate against this problem. The first report
analyzed the problem mainly at the MTP and Recrush plants whereas this report will be
more focused on the Red Area, which is the final plant in the diamond recovery process,
and will also include a full analysis of the recommendations which were mentioned in
phase 1 report.

Also discussed is background information on general power quality problems which can
be experienced by the mine. A more specific definition of voltage dip is suggested and
voltage dip types are investigated for different phases using a software model in which
parameters such as line impedance, dip duration/magnitude, AVR efficiency, parallel
capacitance and total load can be varied to analyse what happens to the sine waveform
of the ac signal under different conditions.

The research for this project was carried out at Debswana Diamond Mine in Jwaneng,
Botswana.
1.1 Project Objectives & Scope
Even though voltage dips are not new to the mining industry and have been known by
most industries as a major power quality problem, very little has been done to try and
guard against this problem. There have been a few researches on this subject to analyse
causes and effects of voltage dips but they rarely ever offer mitigation choices.

This report aims to go one step ahead to recommend the way forward in minimising or
eradicating the undesirable effects of voltage dips.
1.2 Background Information
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1.2.1 Power Quality Issues
The main power quality problem that is encountered by the mine is voltage dips (sags) as
defined in Section 1.2.2 below which is the main focus of this report. Other power
quality issues which this report shall not dwell much upon but may directly or indirectly
affect the occurrence or severity of voltage dips and hence shall only be discussed briefly
for that sake as shown in Figure 1.1 are;

Figure 1.1
[Note that for cross referencing to Figure 1.1 the name indicated in the picture is given
in square brackets below]

Interruptions (blackout) [Voltage Dropout]
Complete loss of voltage on one or more of the phase conductors,
Swells (surges) [Surge]
Temporary increase in rms voltage or current of more than 10% of the
nominal value at a power system frequency which lasts 0.5 cycles to 1
minute,
Transients [Negative & Positive Impulse Spike]
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Unidirectional impulse of either polarity or a damped oscillatory wave
with the first peak occurring in either polarity,
Over voltages [Over voltage]
Where the voltage has a greater value than nominal for a period of time
greater than 1 minute,
Under voltages [Under voltage]
Where the voltage has a lower value than nominal for a period of time
greater than 1 minute,
Harmonics
Sinusoidal voltages or currents having frequencies that are multiples of the
fundamental power frequency,
Interharmonics
Sinusoidal voltages or currents having frequencies that are NOT integer
multiples of the fundamental power frequency,
Notches
Periodic voltage disturbances lasting less than 0.5 cycles,
Voltage fluctuations (flicker)
Systematic variations in the envelope or a series of random voltage
changes with a magnitude which does not exceed the voltage range of
0.9pu to 1.0pu.
1.2.2 Definition - Voltage Dip
Voltage dips/sags usually carry several definitions according to different authors but most
usually have a similar basis a shown in phase 1 report of this research. However for the
purpose of this report a voltage dip shall be defined as a reduction in nominal voltage to a
value less than 90% up to the time when it goes above 90% but for a period more than
20ms and not exceeding 3s.

In this report a voltage dip to X% means that the voltage dropped by X% from nominal,
i.e. a 10% dip means that the voltage a test node will be 90% of nominal. In the Figure
1.2 below the allowed voltage levels are 10%
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Figure 1.2

Disturbances that last less than 1/2 cycle are commonly called "low frequency
transients"; voltage reductions that last longer than a few seconds (i.e. > 3s) are
commonly called "under voltage"
4
as defined in Section 1.2.1 above.

When there is a fault on a transmission line or anywhere in the system, excess current is
drawn from the supply and because current (I) is proportional to (V) voltage (V = IZ
Ohms law) this causes a minor drop in the voltage for the duration of excess current
being drawn as impedance (Z) stays constant. If the fault is not cleared within a short
time as determined by protection settings either an under voltage as described above or a
blackout will result.

The terms sag and dip shall be taken to be the same and so shall power dip and voltage
dip and hence will be used interchangeably in this report.
1.2.3 Voltage Dip Types
This was investigated using Alex McEcherns Concept Teaching Toy obtained from
Power Standards Labs to obtain the following graphs.

4
www.powerstandards.com/tutorials/sagsource.htm, accessed 14 June 2006
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Figure 1.3(a, b, c)
Figures 1.3 above and left shows a
simulation of a circuit which reacts to
changes in the input impedance, the
smoothing capacitance, regulator
efficiency and the load. The simulation
in Figure 1.3a assumes an ideal balanced
network experiencing a three phase
voltage dip due to a fault. The dip lasts a
total of three cycles (60ms on a 50Hz
network). Of most interest is the Volts regulated line as this indicates the voltage being
fed to machine power electronic equipment.

The simulations show that increasing the capacitance [Appendix A1] and the regulator
efficiency has the desirable effect of smoothing out the regulated voltage. For exactly the
same circuit a phase-phase to phase fault (Figure 1.3b) that experiences a similar fault
current would only result in low frequency transients but no actual voltage dip whereas
a single phase fault (Figure 1.3c) would have negligible effect on the terminal voltage.

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Increasing the load increases both the magnitude and duration of the voltage dip
[Appendix A2]. This is due to the fact that a larger load draws more current thereby feels
the onset of the dip immediately when the fault occurs and a higher voltage drop.

Emphasis should be made here that even though this particular voltage dip (Figure 1.3a)
lasted no more than a mere 60ms the corresponding interruption to the diamond mining
process may have been extremely large. For example some drives might have stopped
resulting in Head feed delays that can last for several hours leading to long start-up
procedures both of which translate into appreciable revenue losses.
1.2.4 Selected Literature Review
There have been several studies covering the voltage dip phenomenon. The following is a
selected few of some of the reports that have been published about voltage dips.

G.J COETZEE, Power Quality paper #1 Causes of voltage dips & resulting problems,
Switching Systems Electronic Engineers

POHJANHEIMO P., A Probabilistic Method for Comprehensive Voltage Sag
Management in Power Distribution Systems, Doctoral thesis, Helsinki University of
Technology, 2003

J. D. MASTERS, Dowding Reynard & Associates (Pty) Ltd, Voltage Dip study at
Jwaneng Mine-addendum, 13 March 1997

ABBAS AKHIL, SHIVA, SWAMINATHAN, RAJAT K. SEN, Cost Analysis of Energy
Storage Systems for Electric Utility Applications, February 1997

MATH BOLLEN, Voltage Sag Indices Draft 1.2, working document for IEEE P1564
and CIGRE WG 36-07, December 2000

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With exception of the voltage dip study done at Jwaneng mine by J.D Masters, all of the
above researches were more academically inclined and do not offer any recommendation
on what should be done to avoid this unwanted situation. Even J.D Masters offers only
one solution in the form of Dip Proofing Inverters and hence does not really give a broad
choice or reason why DPIs may not the best nor does he state the draw backs of this
particular apparent panacea (as is the general feeling in the mine). However all these
shed some very vital information on the causes and effects of voltage dips on power
electronic equipment.
1.3 Project Methodology
Research for this project was carried out as follows;

Initially, prior to research at Jwaneng Mine, an extensive literature review on the subject
of voltage dips was carried out using published journals, textbooks, the internet,
magazines and all publications that mentioned this problem.

Knowledge of the other plants within Jwaneng Mine from Previous attachments to the
following sections in the specific years was used;
2002 EM15 Electrical Workshop
o Shovels & Drills
o Pit electrical reticulation maintenance
2003 Recrush plant
o General mining process flow
2005 EE12 Electrical Services Workshop
o Maintenance of diesel standby generators
o Overall mines electrical reticulation

Gathering of information was generally done using questionnaires and short discussion
meetings for the respective mine personnel for Electricians, Section, Engineers, Senior
Plant Metallurgists, Electrical Workshop foremen, BPC & NCC.
_______________________________________________________________________

There was attendance of Daily production meetings at the MTP to gain knowledge of
how this issue is tackled and what form of feedback is demanded by the non engineering
management.

Email correspondence of the Daily exception report and the Daily production report both
from the MTP and the RP was used to analyse delays caused by several factors on the
plants.

A general tour of the Red Area Plant was done to get an appreciation of the general
diamond mining process at the final point in the mine and identify where critical loads
are located.
1.4 Thesis Outline
This report is organised into 11 chapters which are as follows;

Chapter 1 - The first chapter offers background information on different power quality
problems that the mine encounters and broadly defines the term voltage dip/sag. A
software model is used in order to investigate the different types of voltage dips that the
mine may experience to establish which ones will trip out drives and damage power
electronic equipment. Also discussed here is a literature review of selected researches
that have been done on this subject.

Chapter 2 defines the methods of recording of voltage dips that have been found at
different sections and plants within Jwaneng mine. The methods here are different
according to who does the recording be it the section engineer at electrical services,
electrical workshops, treatment section, CCR, BPC or the Red Area Plant. This chapter
also analyses probable causes of voltage dips in the red area plant

_______________________________________________________________________
Chapter 3 discusses the effects of voltage dips on the red area plant processes at Security,
Bulk Acid Handling Facility, FISH & CARP, internet servers, air conditioning and
general diamond production process.

Chapter 4 presents an economic evaluation of the apparent financial losses encountered
due to head feed delays, FeSi losses and security breach that have been caused
specifically by faults on the electrical reticulation network that led to a voltage dip. The
cost to the mine due to dips has never been documented so this report makes some sound
assumptions on some production figures.

Chapter 5 elaborates briefly what has already been presented in the Phase 1 report on
supply utility (BPC) conditions on the quality of supply. This chapter looks at the agreed
levels of voltage supply on magnitude and balance, frequency deviation and allowed total
harmonic distortion.

Chapter 6 is a list of the most critical loads within Jwaneng Mine as presented by the
engineering manager. However this list is incomplete for the red area on the basis that the
records of the drives/machines that trip due to dips are not listed even though they are
very critical to the entire process. These drives are mentioned in Chapter 3.

Chapters 7, 8, 9 and 10 offer several different recommendations to the mine;

Chapter 7 offers ways in which to reduce the frequency of occurrence of voltage dips by
analysing what happens to the system with power quality meters, establishing proper
protection and grading margins, testing power electronic equipment (contactors) with sag
generator, balancing the network, minimising THD, power factor correction, soft starting
large loads and proper earthing methods. The last of this chapter part suggests reducing
equipment sensitivity in order to fall within the limits of the ITIC curve

Chapter 8 discusses in detail some of the ways of compensating the missing due to a
fault. Compensation is by means of energy storage systems such as the SMES, BESS,
_______________________________________________________________________
FES or UPS. Closing this chapter is a case study to compare costs of existing SMES and
BESS. A technical and cost analysis of the above methods discussed therein and a point
of connection to the existing electrical reticulation suggested. If the mine chooses one of
the energy storage systems recommended here then a power conversion system shall be
needed to connect to existing system. This chapter suggest a model for such a conversion
system.

Chapter 9 Smoothing out Voltage Profiles - Mentioned in this chapter is use of switches
namely the SETC or LTC and the SSTS to transfer load to alternate supply to avoid a
voltage dip. The SVC is also discussed in detail to offer MVAr injection and thus sustain
voltage at nominal level. Also here a technical and cost analysis of the above methods
discussed therein and a point of connection to the existing electrical reticulation
suggested.

Chapter 10 addresses general power quality mitigation against problems such as Ferranti
effects, blackouts, surges, over & under voltages, harmonics & interharmonics, notches
and flicker. This chapter also presents a procedure that Jwaneng mine will be
recommended to use to report and record power dips.

Chapter 11 - The last part of this report reviews the objectives for this project in order to
analyse whether they have been properly met and points out what shortcomings were
encountered. This part also discusses, concludes and suggests future work on mitigation
of voltage dips at Jwaneng mine.
_______________________________________________________________________
2 Current Methods of Recording of Dips
These methods of recording of dips were found at the RP, MTP and Mining Electrical
Workshops and include the Balanced Score Card, Power Dip Record Sheet, Electricians
shift reports, CCR reports and BPCs daily reports. Electricians at the Red Area
workshop have no absolute defined recording method of power dips. The causes of
voltage dips for different sections were discussed in Phase 1 report except for the Red
Area Plant which shall be discussed in the last part of this chapter.
2.1 Balanced Score Card (Use of power quality meters)

Figure 2.1 - Source: KENNY SINYINZA, Power Quality Metering Output, Jwaneng Mine

The graph above shows data as downloaded from power quality meters that are installed
on the supply utility side at the mines main switchyard. It shows a dip that lasted less
than 164ms and the voltage dropped about 4kV from nominal on two phases. The data
collected from the meter is used to compile the following graphs called the Balanced
Score Card.
_______________________________________________________________________
IP5: POWER DIP FREQUENCY
5
7.0
4.0
2.0 2
0
2 2
1 1
0
1
2
3
4
5
6
7
8
Jan-06 Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07
Actual Internal External Threshold Target Stretch Target

Figure 2.2 Source: KENNY SINYINZA, Balanced Score Card, Jwaneng Mine

The balanced score card is kept every year and it can be seen that there were 34 voltage
dips last year [Appendix A3] from January to October 2005 and there has been 26
voltage dips this year (2006) in the same period Figure 2.2 . This can hardly be called
an improvement as it can also be seen that the frequency of occurrence is spread out over
the months this year than last year where there were no dips between June and
September. For the two years the months in which most power dips are experienced are
from January to March. It can also be noted that for these particular years most
thunderstorms occurred during this period which may account for the higher frequency of
occurrence of voltage dips as corroborated by reports from the mine and BPC see
Appendices report Phase 1.
2.2 Power Dip Record Sheet
The Voltage dip recording sheet shown in [Appendix A9] had been made for the mine
but it is rarely ever used. Adjustments were made to include feedback and comments
comprising dip magnitude and duration, total load shed and comments from treatment,
BPC and electrical services workshops. This is further discussed in detail in Section 10.8
2.3 CCR
_______________________________________________________________________
CCR Operators generally record power dips whenever they see the lights dim and any
drives were interrupted. Any head feed delays will therefore be accounted for as being
caused by a voltage dip.
2.4 Electrical Workshop
None of the electrical workshops in the mine have access to any power quality meters
and personnel are not even aware that there is a power quality meter at the mines main
switchyard. The workshops will report a power dip as source of fault if none other can be
seen when any machines/drives need to be reset.
2.5 BPC
BPC does not have any specific record of dips that can be made available for the mine
but all faults that occur on transmission line and on the network are documented daily
and these were obtained from their NCC and comparisons made with dates and times
when the mine reported a voltage dip. See Appendices Report Phase 1.
2.6 Red Area Plant
At the Red Area, CCR usually reports that a machine has stopped and the electrician who
has to reset it will report that as a power dip if not other fault is apparent. The foreman
takes this to the daily production meeting as cause of machine trip. However feedback is
neither given nor demanded by the attendees at the daily production meeting on what was
the cause or what is being done to resolve the problem and hence voltage dips are not
documented anywhere.
.
For a plant that does not document voltage dips it makes it difficult to ascertain what
faults on the transmission system lead to this particular problem. However cross
referencing from the electricians at times when they are called to reset machines some of
the following can be attributed to be probable causes at these respective areas;
_______________________________________________________________________
2.6.1 Treatment
The power dips that originate from within the plant are mainly caused by bad weather.
The most frequent occurrences of machines/drives tripping are during the rainy season
and as such only a correlation of coincidence can be made that voltage dips are the cause.
Some of these alleged voltage dips however may have been just another power quality
problem and not a voltage dip.
2.6.2 External to the Red Area Plant
Most of the alleged power dips that affect the Red Area are from faults that are external
to the plant and either originate from mining section or outside the mine altogether as
stated in project report phase 1.
2.6.3 Security
There are no reported cases of a situation whereby a voltage dip was caused by an
individual tampering with the security system of the plant but the fact that it has not
occurred yet does not mean it will never do.
_______________________________________________________________________
3 Effects of Power Dips in the Red Area
The start-up procedure of the processes in the Red Area plant is not as tedious as that of
the MTP and the Recrush plants. However appreciable delays are encountered whenever
there is a power dip as certain drives trip and lights go off even creating a security risk.
This chapter analyzes the effects of voltage dips on the security of the plant, the potent
acids being used and the delays on the general process.
3.1 Security
A major impact on the security of both the employees of the company and the diamonds
would be encountered if a power dip caused security system failure and if the lights were
to go off.
3.1.1 Magnetic Locks
Most of the security locked doors in the Red Area use magnetic locks which depend on
the presence of power to be able to work. When a voltage dip occurs at the instance when
the door was open it will not be able to lock back on leaving the area unsecured which is
a very high security risk. The door will have to be manually closed even when power
comes back on as the magnetic locks have a limited operating distance.
3.1.2 Central Command Centre
The cameras on the floors (CARP and FISH) may trip out when there is a voltage dip and
security officers will not be able to monitor what is happening. The protection system is
offered by onsite technicians and they have to be called in to reset but there will be a
definite delay. During this time no one can be allowed in or out of the Red Area plant at
the main access gate. Employees knocking off will not able to out of the Red Area and
those reporting for duty will not be able to come until the system has been brought back
online.
_______________________________________________________________________
3.1.3 Back-Up System
Back-up in the Red Area is given by means of a diesel standby generator which monitors
the mains supply and automatically switches on when there is a power failure (or power
dip which causes machine failure and lights to go off). The parameters of the generator
are as follows;
Table 3.0 Red Area Standby Diesel Generator
3 Phase, 50Hz, 0.8 p.f
Power 350kVA, 280kW
Output Voltage 550V
Output Current 367A
Revs 1500rpm
Excitation 26V, 2.6A, 0.9 AVR

As can be noted by the ratings on this generator its only used to power up lighting and
very few critical loads just for the security system to stay online and general production is
not accounted for which means the diamond treating process will have stopped in this
instance.
3.2 Acid Handling (BAHF)
The Red Area plant uses Hydrofluoric (HF) acid and Nitric Acid (HNO
3
) [Appendix A5]
in the production process to clean the diamonds by removing surface impurities such as
silicates and water stains before delivering to the Size Frequency Distribution Unit
Process for auditing..
3.2.1 Scrubber
If a power dip were to stop the scrubber in the FISH plant then the acid fumes can not be
extracted from the plant which means a build up will result thereby affecting the health
and safety all the personnel who may be in the vicinity. Compensation charges for the
affected employees on the mine could cripple the mine revenue and any safety audit
could ultimately lead to closure of the mine if such a situation could ever occur. The
motor that runs the scrubber has the following details on its nameplate;
_______________________________________________________________________

Table 3.1 Acid Fumes Scrubber Motor details
Power 110kW
Voltage 525V
Current(Full Load) 151A
Revs 1480rpm

3.2.2 Neutralization Process
Lime (CaCO
3
) and Potassium Hydroxide (KOH) are used to neutralize the used acids
before they can be disposed of [Appendix A5]. When there is a power dip and that causes
the neutralization process to stop then the rest of the diamond process has to stop and this
obviously translates into some appreciable revenue losses in terms of the lost hours of
treatment.
3.2.3 Compressor
The compressor in the Red Area sometimes stops when there is a voltage dip. This is
used to supply air for the air valves and therefore because continuous operation is
required backup is provided by 3 other compressors located at the MTP. However the
process of transferring to MTPs compressors is manual and hence a definite time delay
is experienced due to the unplanned stoppage. The drive for this compressor is rated
110kW.
3.3 General process
Diamond rich material from the MTP and the Recrush is fed to the red area via 3 feed
preparation conveyors whose drives are each rated 11kW. There are also four (4) other
conveyors (named SICON) whose drives are each rated 7.5kW which feed tailings to the
RP and reload from the Red Area old dump for reprocessing when the feed preparation
are not delivering at nominal capacity. Two (2) pneumo blowers both rated 110kW are
used in the diamond treatment process, after the material is heated up using several
_______________________________________________________________________
heating elements they blow it up a channel up to the to of the CARP building to the 15
th

floor to dry it up.
3.3.1 Pneumo Blower (Drier System)

Even though these are each fitted with DPIs rated
3kVA at the Pneumo Drier 550V MCC AKX-230-09
(the same DPIs installed at MTP DMS as documented
in phase 1 report) they are most prone to tripping when
there is a voltage dip according to reports by the
electrical workshop. The DPIs have been in operation
since the time of commissioning of the plant in 1999
and they were put up by a contracted company. When
the Pneumo blower trips all the material that was in the
vertical section of the pipe falls down and can lead to
blockage and major delays will be encountered whilst
the blockage is cleared before they can be restarted.
3.3.2 Feed Preparation Conveyors
If all the 3 feed preparation conveyors stop, then no material is fed from the blue area via
the 110 Ton Bin. However the drives running these conveyors usually trip due to voltage
dips creating head feed delays in the time when an electrician has to be called to reset
them.
3.3.3 SICON
The drives that run the SICON also usually trip whenever there is a power dip and have
to be reset. However as there is material on the conveyors when they are restarted it
means the drives are starting on full load, high currents result and sometimes a second
voltage dip results.
Figure 3.1
_______________________________________________________________________
3.3.4 Perm Rolls
Also affected by voltage dips are Perm Rolls. These are used to separate magnetic feed
from non magnetic to recover diamonds and liberate the waste. When the perm rolls stop
the entire process has to stop otherwise all the diamonds that were in the feed at that
particular time will pass as waste.
3.4 Internet Server Downtime
The servers are generally protected by UPS such that in most cases they are protected
against power dips. However the UPS is connected directly online which means that
during its maintenance or a breakdown when the protected load is connected via the
bypass switch it is left vulnerable to all effects of bad quality power including voltage
dips. A voltage dip can therefore cause bit errors in data transmission and some erratic
telephone switching system performance.

Network downtime can cost in excess of US$50,000 per hour when one megabyte of data
needs to be restored or recreated.
5

3.5 Air Conditioning
Voltage dips sometimes cause the air conditioning units to trip out. For the Red Area
planning offices the distribution board is located in a room that is usually left locked and
such that when there is a trip and the holder of the keys is not around they can not be
reset until he/she comes back. In a country where temperatures can soar as high as 40C it
makes it unbearable for anyone to do any work in the office which has a serious impact
on productivity.

5
http://www.power-innovations.com/about_power/dyk.html accessed 6 November 2006
_______________________________________________________________________
4 Economic Evaluation (Losses due to Voltage Dips)
This chapter presents an economic evaluation of the losses encountered due to voltage
dips outside the mine and within the Red Area by head feed delays, FeSi losses and
security breach. However as this particular plant is the last point in the treatment
process and encompasses both the RP and MTP reference shall be made to revenue
losses for the entire mine as shown by head feed delays on the balanced score card.
4.1 Losses due to Bad Power Quality
Power Innovations Inc, a technology company located in Lindon, Utah, has the following
facts and figures published on their website about the financial losses that are
encountered due to voltage dips;

A recent rolling blackout in the greater San Francisco Bay Area
caused an estimated US$75 million in losses in the Silicon Valley.

According to Larry Owens of Silicon Valley Power, a blackout
costs Sun Microsystems up to US$1 million per minute

Every hour of downtime for a typical mid-sized network costs its
owner US$18,000.

Poor power quality costs U.S. businesses more than $26 billion
each year!

80 to 90 percent of power glitches come from voltage sags, which trip motors and
microprocessors, according to Gregory J. Yurek, CEO of American Superconductor
_______________________________________________________________________
Corp. of Westborough, MA, another superconducting technology leader. Yurek estimates
that sags cost U.S. industries about US$12 billion a year in downtime.
6

4.2 Production Delay (Head Feed Delays)
IP4: Head Feed Delay due to Power Interruptions and Dips
3.3
6.5
2.2
0.85 0.83
0.0
0.9
0.5
1.3
0.5
0
1
2
3
4
5
6
7
Actual Internal External Threshold Target Stretch Target

Figure 4.1 Source: KENNY SINYINZA, Balanced score Card, Jwaneng Mine

The graph above shows head feed delays that occur due to power dips for the entire mine.
However any head delays encountered by MTP and RP will directly be transferred to
delays in the Red Area plant as well.

The balanced score card above shows that the mine lost 15.08 hours from January 2006
to October 2006 due to power dips. Except for the month of February the amount of
delays is generally below both the threshold target and the stretch target of acceptable
amount of delays that the mine can tolerate. However these targets are artificial and were
computed looking at past trends and can be further analysed such that they can be
brought closer to the zero line which would be the most desirable condition.

For the same period last year (2005) the balanced score card shows that the mine had
delays amounting to 19.83 hours due to voltage dips. Again from this data there is hardly
any improvement and averages verify this;

6
http://www.pur.com/pubs/1251.cfm accessed 7 November 2006
_______________________________________________________________________
From Section 2.1 there were 36 voltage dips in 2005 this gives an average of;

19.83/34 = 0.58 hours/dipEquation 4.0

And there were 26 voltage dips this year (2006) giving;

15.08/26 = 0.58 hours/dipEquation 4.1

If the data from last the years 2005 and 2006 can be taken as to reflect a general trend on
voltage dips at Jwaneng mine there on average there is a delay of 0.58 hours for every dip
Equations 4.0 and 4.1 and it has not changed from the year 2005 to 2006.

The Red Area experienced a total of 24 hours of head feed delays due to power dips
alone in the period between the 20
th
of December 2005 and the 10
th
of April 2006 as
shown in [Appendix A4].

In the year 2005 alone the mine produced 15 618 155 carats. This was a record figure for
the mine but if this production figure was achieved again in the year 2006 then on
average it can be assumed that the mine achieves;

15618155 carats / (1year*365days/year*24hours/day) = 1782carats/hourEquation 4.2

And if the cost per carat bought from the mine was assumed constant at an average of
US$140 as mentioned in Phase 1 report then the profits foregone by the mine due to these
delays would be;

US$ 140/carat*24 hours*1782 carats/hour = US$ 5 987 520 Equation 4.3

Which is equivalent to BWP 37 402 241.11 as computed from the currency converter at
http://www.xe.com/ucc/convert.cgi accessed 1 November 2006.

_______________________________________________________________________
However if the current carats production statistics are assessed for the period from
January 2006 to September 2006 [Appendix A5] then on average Jwaneng mine has been
producing 1 289 758.28 carats per month from the red area plant. If this is extrapolated to
the end of the year (December 2006) the mines carat production for the year 2006 will
be 15 477 099.33 which is about 1766 carats/hour which is still close to the value
calculated in Equation 4.2 of 1782 carats/hour.
4.3 FeSi Losses
Ferro Silicon (FeSi) is used in the mining process to aid in separating the diamond rich
material from the waste a process referred to as Dense Medium Separation. Magnetic
rollers are used to recover the FeSi so that it can be re-used. If the drives running the
magnetic rollers stopped due to a voltage dip then all the FeSi in that particular stream
would be lost.

In the red area FeSi is only used at the BSP which is a small plant used for research
purposes [Appendix A5]. In contrast to the MTP and the Re-crush plants loss of FeSi in
the red area is very minimal. At any instance no more than 1 bag of FeSi would be in
circulation in the process cycle. That means a loss due to a stoppage of the plant by a
power dip would amount to about ZAR 6000 which equates to about BWP 5 064 see
currency converter section 4.2.
4.4 Security Breach
There are no definite economic losses that can be attached to a security breach caused by
a voltage dip. Exit points of the red area are via search points which have X-Ray
machines. If a voltage dip affected these machines it would make it possible for any
individual to exit the plant with diamonds or other valuables.
_______________________________________________________________________
5 Supply Utility Conditions
Supply Utility Conditions were mentioned in Phase 1 report in more detail but Sections
5.1 on supply clause/provision and 5.2 on power quality specifications are mentioned
here for reference and for more elaboration. Also harmonic compatibility levels as
stipulated by BPC are discussed in this chapter and compared with actual (measured)
levels seen at Jwaneng mines power quality meters. Also assessed here is effect on
quality of supply of the proposed 220kV line from Morupule to Thamaga substation.

Jwaneng mine is supplied at 132kV and hence is classified by BPC as being on the
transmission network rather than the distribution network. The two 20MVA transformers
at the mines switchyard step this down to 6.6kV and two lines both of which are rated
1250A supply the Red Area.
5.1 Stipulation
The Corporation shall not be liable for damages, expenses or costs caused to the
consumer from any interruption in the supply, variation in voltage, variation of
frequency, any failure to supply a balanced three phase current or failure to supply
electricity whether the said interruption is or is not due to the failure of the Corporation to
carry out its obligations or to any other cause whatsoever.
7

5.2 Power Quality Specifications
5.2.1 Voltage & Frequency
The fundamental specifications as mentioned in phase 1 report for the quality of supply
as stipulated by NCC are;
Voltage: 10%
Frequency: 2.5%
Voltage (Phase) Unbalance shall be maintained at 2%

7
Bye Law #31, [CAP. 74:01 S.I, Botswana Power Corporation (Electricity) Bye-Laws under section 28,
21
st
December 1979
_______________________________________________________________________
The highest unbalance measured for the month of December 2005 was 0.63% whereas
the highest frequency was 100.17% and the lowest was 99.82%. Table 7.0 below shows
the highest voltage deviation from stated nominal by % for the same month.

Table 5.0 Operating voltages per phase
Voltage Phase Highest (%) Lowest (%)
Red 104.74 100.51
White 104.04 101.31
Blue 105.23 102.02
5.2.2 Harmonics
Table 5.1 below was extracted from BPCs daily Operations and Transmission December
2005 Jwaneng Power Quality Report. The power quality standard used by BPC was the
NRS 048 - 2(2003). The table shows the targets that the supply utility stipulates to be
able to meet everyday.

Table 5.1 Harmonic Compatibility Levels (according to NRS 048-2)
Harmonics
Order Harmonic Voltage (%)
3 5
5 6
7 5
9 1.5
11 3.5
13 3
15 0.5

Table 5.2 Measured Highest Harmonic Voltages
Harmonic
Order
3 5 7 9 11 13 15
Red (%) 0.65 3.70 0.36 0.01 0.07 0.10 0.03
White (%) 0.80 3.51 0.32 0.00 0.08 0.07 0.02
Blue (%) 1.23 3.80 0.25 0.01 0.08 0.10 0.02

Harmonic order 5 seems to be the most dominant but it is still within BPCs acceptable
limits.

_______________________________________________________________________
NRS 048 2 specifies that the THD should be less than 8%.

Table 5.3 Total Harmonic Distortion (THD)
Voltage Phase % THD
Red 3.99
White 3.78
Blue 3.98

For the month of December 2005 the THD was within acceptable limits across all phases
as defined by the supply utility.
5.3 Proposed 220kV Transmission Line
The BPC is currently undergoing a project erecting a 220kV transmission line from the
generating power station at Morupule to the substation at Thamaga from which Jwaneng
is fed. The table below shows the improvement on the fault level ratings. This project is
scheduled do be finished by December 2006.

Table 5.4: Comparison of fault level ratings with and without 220kV line

Without Line

With Line

Busbar (kV) MVA KA MVA KA
132 438 1.92 493 2.158
33 231 4.43 270 4.73
6.6 208 19.96 242 21.14
_______________________________________________________________________
6 Critical Loads
Companies that sell power quality products require that the customer specify the kind of
equipment that is most vulnerable or most critical/essential to operations. This chapter
shows a list of Jwaneng mines most critical loads. The list was obtained from Jwaneng
mines intranet pages and was made in June 1996. The intranet pages however indicate
that it was last modified on 24
th
January 2005.

Some of the equipment may have since then evolved and more equipment may have
been added as well but this is the only list available from the companys intranet pages.
These are the loads that always have to be working to avoid a major production
downtime or breach of security within the mine premises both of which could lead to
substantial revenue loss and even hamper safety of personnel.

Some of the loads such as general plant lighting and low power control equipment have
always had a back up system for the case of any power fluctuations. Back-up is in the
form of UPS for some control equipment and small auxiliary generators (350kVA at the
main switchyard). The larger loads such as the slurry pumps require more power and can
not be compensated by UPS or the small auxiliary generators. The DMS streams at MTP
and some critical drives have protection against dips in the form of DPIs.
6.1 Red Area
Some of the most critical loads in the high security plant of Jwaneng mine as listed on the
intranet are as follows. However it should be noted that Chapter 3 details some other
machinery that is not listed here but has been more prone to tripping during voltage dips
and quite essential to the diamond recovery process

Heating elements for grease applicators 200 kW
o This is only used in the small Bulk Sampling Plant within the Red Area
Security / lighting150 kW
_______________________________________________________________________
CAC150 kW

Sub Total 500 kW
6.2 Main Treatment Plant
Most of the following critical drives correlate well with the ones discovered and reported
in appendices in Phase 1 report.

Thickener rake drives (6)180 kW
Thickener underflow pumps (1 set)112 kW
Submersible pumps 40 kW
Slurry pumps (2 of)220 kW
One (1) DMS stream400 kW
Plant lighting250 kW
Compressor (1 of)160 kW
Fire pump75 kW
Jet sump pump and sump pumps260 kW
Degrit stream (1 of)100 kW
JX118 and node conveyor165 kW

Sub Total 1962 kW
6.3 Re-crush Plant
The re-crush plant being a recovery plant with operation very similar to the MTP ideally
has similar critical drives but the following are those obtained from the intranet site.

Ensure that the BPC 132/33kV transformers and the 33kV township feeders have
been isolated by BPC prior to supplying power through the standby emergency
step-up transformer (5MVA 6.6kV/33kV).
Thickener rake drives (5)150 kW
_______________________________________________________________________
Sump pumps in thickeners200 kW
Lighting250 kW

Sub Total 600 kW
6.4 Services
Services entail general provision of electricity and maintenance and this is located outside
the mining area and hence has not drives directly linked to the diamond mining process.

There are no critical loads
6.5 Open Pit
The open pit is where the kimberlite is blasted. It should be noted that the 205 Shovel
which has an induction motor rated 2MW discussed in section 3.3.1.3 of report phase 1
is located in the open pit but the report on critical loads for this area is as follows

There are no critical loads

The total power requirement for critical loads is: 500+1962+600 = 3062 kW
8

8
DEBSWANA DIAMOND COMPANY (Pty) Ltd, Jwaneng Mine, Engineering Electrical Services
Standard Procedure, Procedure No: EE-E1-06, Critical Loads to be supplied from the Power Station Diesel
Generators during a BPC Power Supply Failure, Revision 1, 7 June 1996
_______________________________________________________________________
7 Reducing Occurrence of Dips
This chapter was briefly introduced in phase 1 report. It has been established in previous
chapters that voltage dips are an inevitable phenomenon and will always occur due to
some unavoidable faults on the system. However some of the artificial faults can be
minimised at least to a considerable level. The different methods of reducing the
frequency of occurrence of voltage dips are discussed in more detail here.
7.1 Power Quality Metering
This is perhaps the most vital aspect of voltage dip mitigation. The best way to solve any
problem is to know what exactly the problem is and validate whether indeed a problem
persists. This should be installed on the mines side switch yard and then at points of
connection to only the most critical processes. With a Power Quality meter in place one
can compare against the voltage dip window as mentioned in Section 5.2 of the report for
Phase 1 and thus know how best to protect equipment with knowledge of the most
prevalent type of dips according to magnitude and duration.

Quote requested from Haefely Technology on 12/07/06 was CHF 18 600 for the PLINE
1610 and CHF 19 500 for the ECOMPACT4 testers. CHF 19 500 equates to about BWP
93 135.84 (www.xe.com/full)
7.2 Protection & Discrimination
This is another power quality aspect that may often be overlooked but if properly done
the effects of some voltage dips arising from faults on the network can be reduced such
that only part of the network with the fault that caused a voltage dip is disconnected. This
should be done in a clear and concise way such that any electrician can be able to
pinpoint which timers may need to be changed when a new machine is added into the
system.

_______________________________________________________________________
The current criteria within the mine is not clearly defined in the sense that sometimes
grading margins are arbitrarily chosen with no proper calculation or template in the form
of software package such that every time a new unit is incorporated into the system
discrimination becomes a big hassle. Most of the settings have to be changed every time
there is a fault after realization that circuits closest to the fault that were supposed to trip
stayed online an only distant circuit breakers operated (geographical grading) thereby
posing risk of damage to drives nearest the fault.

Relay timers should be set such that they can ride through a dip on a site with DPI
installed at least for the duration of the time setting on the DPI.

ARC dead time should be incorporated into any protection and discrimination settings as
otherwise this could lead to loss of supply and thus render any voltage restorers useless

In order to set proper protection and discrimination the following information should be
sought out and known;
A single line diagram showing;
o Load current for each connected machine
o Maximum fault current at each busbar
Impedance seen at each busbar
Line voltage
Fault level MVA ratings at each busbar
PSM as a percentage for each relay
CT ratio of each relay
Required grading margin and TMS plug setting increment value.
7.3 Simulate Bad Quality Power
This is just as useful as metering. It is necessary to simulate bad quality power so as to
fully understand what goes wrong with equipment when there is a power dip and how
best to provide a solution. This would aid in certifying whether equipment used in the
_______________________________________________________________________
mine conforms to standards such as the SEMI F47, whether it lies in the required
tolerance envelopes of the CBEMA or ITIC curves

Simulating bad quality power may even be necessary after purchase and installation of
voltage restorers to test whether they are indeed in good working order and what up to
what level/severity of a voltage dip the would be able to provide a reliable compensation.

Figure 7.1 shows a sag generator being
used to test the operation of a contactor
when there is a voltage dip. The sag
generator produces a dip of known
duration and magnitude. It can also be
used to choose the point-on-wave (sine
wave angle) of voltage dip initiation to
see what effect this will have on the
contactors.
An alternative to buying the sag
generators is requesting that all suppliers
of power electronic equipment to the mine satisfy a pre-determined tolerance to voltage
dips. See reducing equipment sensitivity - Section 7.8

A Quotation was requested [Appendix A6] on June 20th 2006 from Power Standards
Labs via email IPC rated 240V ac, 25A max sells @ US $31 500 (equivalent to BWP
189,072.48 from www.xe.com on 7/4/2006 @ 8:20:55 AM) package including IPC
software.
7.4 Balanced Network & Harmonics
The magnitude and the duration of a dip is dependant on the phase of the voltages at the
time of occurrence such that if large negative phase sequence currents are present at onset
of a dip then it very unpredictable events on the voltage profiles may result. The
magnitude of unbalance in the three phase supply voltage will affect the magnitude of a
Figure 7.1
_______________________________________________________________________
voltage dip as the torque of induction motor drives is dependant on the positive phase
sequence component and thus the presence of a negative phase sequence will reduce the
motor applied torque.
9

A jump in the phase angle of the voltage at the start of a dip can cause some line
commutated variable speed drives to trip even if the dip magnitude is relatively small.
Depending on the phases that are involved in the fault, the negative sequence voltage will
be multiplied by a factor
X
where = e
j120
and X = 0, 1, 2 giving a characteristic voltage
of;
V
1
+
X
V
2
.Equation 7.0

where V
1
and V
2
are the involved phase voltages.
10

Figure 7.1(a, b)
On an ideal 3-phase system, the voltages are balanced (the 3 voltages are exactly equal
and exactly 120 apart) as shown on the Figure 7.2a above. Unbalanced voltages as
shown on the Figure 7.2b above make transformers and motors overheat because part of

9
G.J COETZEE, Power Quality paper #1 Causes of voltage dips & resulting problems, Switching
Systems Electronic Engineers
10
M SCHILDER & RG KOCH, Evaluation of a new 3 Phase dip definition, Energize Power Journal of
the South African Institute of Electrical Engineers, June 2006
_______________________________________________________________________
the voltage or current is trying to rotate the system backwards. The phase voltages
resolve as follows to give the characteristic voltages shown in Equation 7.0;

V
o
= 1/3(V
red
+ V
yellow
+ V
blue
)............. (zero sequence) Equation 7.1

V
1
= 1/3(V
red
+ aV
yellow
+ a
2
V
blue
).......... (red positive) Equation 7.2

V
2
= 1/3(V
red
+ a
2
V
yellow
+ aV
blue
).......... (red negative)Equation 7.3

For the Equations 7.1, 7.2 & 7.3 shown above;
a - rotates 120 clockwise
a
2
- rotates 240 counter clockwise

The approach of the equations above is only valid in absence of harmonics - i.e.
fundamental is not distorted, but more often than not voltages are not pure sine waves on
the ac system. See Figure 7.3 below simulated using Alex McEcherns Concept Teaching
Toy obtained from Power Standards Labs in which the fundamental sine wave is what is
transmitted and the Sum of the waves including harmonics is what the mine may receive.

Figure 7.2
_______________________________________________________________________
It should be ensured that all three phases are balanced to avoid negative phase sequence
currents flowing in the connected drives. Harmonics can be filtered out of the system by
using appropriate filters. A private company called Netlab Group has been contracted
by Jwaneng mine to address this issue. Netlab Group initial recommendation is
installation of filters and capacitor banks at the Recrush plants and in the mining section
latest by mid next year (2007)
7.5 Power Factor Correction
It was mentioned in report phase 1 that the mine does not incur any charges whatsoever
for a bad power factor. Even though this may be true as it is not reflected in any of the
BPC bills, further research into this issue has however revealed that the mine is
contractually bound by BPC to keep the power factor at least above 0.8 lagging.

The power factor observed at the Red Area plant was 0.40 lagging on Incomer N
o
1
delivering 241kVA and 0.69 lagging on Incomer N
o
2 delivering 672kVA at the
Aquariums 6.6kV switchboard AKX-221-01.

Loads with poor power factor increase reactive power losses on the lines and hence could
induce a voltage drop along the transmission lines. That means sudden start-up of
induction loads could cause a transient drop in voltage but if power factor correction is
properly done there would be less reactive power loss and hence no voltage drop.

Also knowledge of the power factor is vital when calculating the minimum up time of a
DPI as shown in Phase 1 report. If the power factor were to suddenly drop or increase
then the up time of the DPI would obviously change and put drives that are assumed to be
protected under risk of damage.

The mine has two capacitor banks connected to the 11kV busbar at the Northern Well
fields where it pumps its own water supply. The primary reason of the installation of such
was the fact that a lot of induction motors are used to pump the water and this in turn
made the power factor lagging and hence needed some form of correction.
_______________________________________________________________________

The SVC can also aid in correcting the power factor see Section 9.3
7.6 Soft Starting Large Induction Motors
The use of soft starting methods such as autotransformers can reduce the inrush current
which can be up to 7 times full load current which would otherwise cause a drop in
voltage. Soft starters control the current delivered to a motor, which then controls the
torque and hence the motor accelerates smoothly.

Where constant speed is required during operation of a motor then soft starter is a better
choice over VSDs as they are much cheaper and less complex. Moreover VSDs may
introduce harmonic distortion on the power network.

Selective start of critical loads should be done both at plant start up and after a voltage
dip/failure to ensure that minimum current is drawn from the supply to avoid a condition
whereby several voltage dips ensue one after the other indefinitely.
7.7 Earthing
Earthing is another aspect of power quality that needs to be fully addressed to limit the
occurrence of voltage dips within the mine. Earthing is useful as it means that current
flow shall be limited to pre-defined nominal levels even in the case of a fault (maximum
fault current) and that no voltage dip shall be encountered in the most ideal operation of
the earth fault protection system employed.

The earthing requirements as stipulated by the Anglo American Corporation of RSA for
Debswana Diamond Company (Pty) LTD in April 1997 are as shown in [Appendix A7].
The document however, does not explicitly lay out the type of earthing to be used or the
reason of choice thereof. Two types of possible earthing methods are hereby discussed.
_______________________________________________________________________
7.7.1 Neutral Earthing Resistor

This is usually for protection against S to
neutral faults Figure 7.4. NERs are used for
resistance grounding of industrial power
systems. They are usually connected between
earth ground and the neutral of power
transformers, power generators or artificial
neutral transformers. Their main purpose is to
limit the maximum fault current to a value
which will not damage generating, distribution
or other associated equipment in the power
system, yet allow sufficient flow of fault
current to operate protective relays to clear the fault.

The following is needed to specify a neutral earthing resistor:

1. The line-to-neutral RMS voltage
2. The initial current in amperes.
3. Allowable "time on" - defined as the length of time that the line-to-neutral
voltage can be applied without exceeding the allowable temperature rise.

For extended time ratings (greater than 10 minutes) the allowable temperature rise is
610C. For continuous ratings the allowable temperature rise is 385C.
11
A Neutral
Earthing Resistor restricts the flow of current during an earth fault on an ac distribution
system. Although a neutral earthing resistor will probably be active for just a few seconds
during its operational life, it must offer dependable protection at all times in case of
fault.
12

11
www.fortressresistors.com/neutral_earthing.htm, accessed 11-Aug-06
12
http://www.irescoindia.com/neutral.htm, accessed 11-Aug-06
Figure 7.4
_______________________________________________________________________
7.7.2 Neutral Earthing Compensator

This is for protection against phase
to phase faults Figure 7.5. The
NER could also be connected via
reactances in a delta system, which is
part of the NEC network. Intuition
says that when there is a fault, then
the voltage should collapse, but often
faults can cause voltage increases of
up to many times operating voltage,
especially when reactive NECs are
used.
13

This type of grounding is often referred to as resonant grounding system. Figure 7.5
shows one way of connecting a resonant grounding system. When the system capacitance
is matched by the inductance of the coil, the system is fully compensated, or at 100%
tuning. If the reactor inductance does not match the system capacitance, the system is off
tuned. It can be over- or under compensated, depending on the relationship between
inductance and capacitance.
14

Resonant grounding a system can reduce the ground fault current to about 3 to 10 percent
of that for an ungrounded system. For 100% tuning, the active coil losses, system
harmonics, and system active leakage current determine the fault current magnitude.
Residual current compensation methods inject a current through the reactor to the system
during the fault, reducing the fault current almost to zero
14

13
NEIL JEFFREY, Dynamic Range Requirements of Capacitor VT Sensors for Protection Systems, SURE
Engineering CC, 23 March, 1999
14
JEFF ROBERTS, DR. HECTOR J. ALTUVE, AND DR. DAQING HOU, Review of Ground Fault
Protection Methods For Grounded, Ungrounded, and Compensated Distribution Systems, Schweitzer
Engineering Laboratories, Inc.
Figure 7.5
_______________________________________________________________________
7.8 Reduce Equipment Sensitivity

Figure 7.6

In most cases the Mine can not do much as far as making its equipment less sensitive to
dips is concerned but it can ensure that it buys equipment that has a higher sensitivity
margin. For example semiconductor device should conform to the SEMI F47 standard
and should be able to tolerate levels indicated in the ITIC curve. This will ensure that at
least most power electronic equipment within the mine can ride through less severe
voltage dips. In Figure 7.6 the lower graph indicates tolerable levels for voltage dips
Power Electronic Equipment should not be affected by dips that last less than 0.5s if the
voltage does not falls below 70% off nominal or dips that last more than 0.5s but less
than 10s if the remaining voltage stays above 80% of nominal. Note that if the voltage
stays at 80% of nominal for more than 3s then the condition is an under voltage.
_______________________________________________________________________
8 Compensate Missing Voltage
This chapter analyses dip mitigating options by means of compensating the voltage with
energy storage devices. A full analysis is discussed in terms of principle of operation,
Cost analysis, Technical analysis and a possible connection on the mine site. The energy
storage systems discussed in this section all need some power electronic circuitry for
switching to the network. This chapter suggests one possible way of doing such a
connection.
8.1 BESS - Battery Energy Storage System
A battery modules basic building
block is the electrochemical cell as
shown in Figure 8.1. A number of
electrochemical cells are packaged
together to form a battery module. The
battery modules are connected in a
matrix of parallel-series combination
to form a string. A string may be
formed to deliver the required voltage
which may range from a few hundred
volts up to approximately 2,000 volts.

A 1-MW/l MWh BESS discharged at
1MW will be able to supply the entire 1MWh of stored energy over a 1-hour period.
However, if discharged at a 2-MW rate, the battery will operate for less than half an hour,
delivering less than 1MWh of energy in the process. The life of a battery is affected by
the manner in which it is operated. The cycle life (the number of charges and discharges
it can perform) of a battery is highly dependent on the depth of discharge, with deep
discharges (>70-80 percent) significantly reducing its cycle life. Batteries also have shelf-
life limitations.
Figure 8.1
_______________________________________________________________________
8.1.1 Cost Analysis

The current cost of one-to two-hour BESS ranges from US$1200 to 1500/kW.
15

However, for the purpose of mitigating against voltage dips compensation of up to 1 hour
is not required. A 2MW - 10s BESS designed specifically as a power quality system is
estimated at US$450/kW which is BWP 2,892.51
16
on 3 October 2006.
8.1.2 Technical Analysis

Advantages:
Cheaper than a comparative SMES unit but as batteries require regular
maintenance (similar way to UPS) it may prove more costly to maintain that a
DPI of similar compensation time/magnitude.
Capable of high power output for a short time.
Disadvantages
Requires further electronic components after installation for a faster switch over
time (such as the SSTS as outlined below).
Might not be able to sustain power for repetitive voltage dips due to sustained
faults whereby load is reconnected by ARC.

15
ABBAS AKHIL, SHIVA, SWAMINATHAN, RAJAT K. SEN, Cost Analysis of Energy Storage
Systems for Electric Utility Applications, February 1997
16
http://www.xe.com/ucc/convert.cgi, accessed 3 October 2006
_______________________________________________________________________
8.1.3 Connection

Figure 8.2
Small BESS units could be installed at the most critical processes in the mine just as the
current UPS systems which are used to compensate voltage for measuring instruments
and PLCs.

The BESS should be used in conjunction with the SSTS (Figure 8.2) as defined in
Section 9.1 to reduce the time it takes to switch from normal supply in the event of a dip.
8.2 SMES- Superconducting Magnetic Energy Storage System
A SMES system, designed to improve
the power quality for critical loads,
provides carryover energy during
voltage sags and momentary power
outages. The system stores energy in a
superconducting coil immersed in liquid
helium.

The superconducting device stores
energy within a magnet created by the
flow of direct current in a coil of
superconducting material. To maintain the
Figure 8.3
_______________________________________________________________________
coil in its superconducting state, it is immersed in liquid helium contained in a vacuum-
insulated cryostat. In standby mode the current continuously circulates through the
normally closed switch. The power supply provides a small trickle charge to replace the
power lost in the non superconducting part of the circuit. When voltage on the capacitor
bank on the dc side of the inverter drops during a dip, the normally closed switch opens
and current from the coil immediately flows into the inverter Figure 8.3.

When the voltage across the capacitor returns to a preset level, the switch closes. The
sequence repeats until voltage from the utility feeder is restored. In many cases the device
can be connected to the dc bus of an existing VSD thus eliminating the need to provide a
rectifier and an inverter
15 above

Test data by The Materials and Manufacturing Directorate and the Power Conditioning
and Continuation Interfacing Equipment showed over 100 events caused by lightning or
power dips that resulted in voltage sags greater than 10%. It has also shown that SMES
systems can effectively protect against dips. Field testing of the Intermagnetics General
Corporation (IGC) SMES by the PCCIE Office indicated that this unit is capable of
providing conditioned power with an output voltage and current total harmonic distortion
of less than 4%
17

8.2.1 Cost Analysis

A commercial 2.2-kWh SMES unit developed by Superconductivity, Inc., suited for
industrial power quality applications, is estimated to cost US$2.4 million equivalent to
BWP 15,426,720.00
18
on 3 October 2006. It has the ability to protect customers from
momentary outages, voltage dips/surges, and its ability to correct harmonic distortions
and power factors. The cost of the storage component is $700,000 and the Power
Conversion System (PCS) cost is estimated at $300/kW.
19

17
http://www.afrlhorizons.com/Briefs/Dec01/ML0009.html, accessed 7 September 2006
18
19
Abbas Akhil, Shiva, Swaminathan, Rajat K. Sen, Cost Analysis of Energy Storage Systems
for Electric Utility Applications, Sandia Report, February 1997
_______________________________________________________________________
A cost analysis could be done such that if smaller units are more economical than one
large unit then several units could be installed at appropriate plants only to the most
critical machines in much the same way as the current scenario with DPI that are already
installed in the mine.

Advantages:
Time delay between charge and discharge is short
High power output for a brief period of time
Low resistance hence low power loss
Main components motionless hence increased reliability
20

Disadvantages:
High cost of superconducting wire
o US$1920/kW for an SMES rated at 1000MW
21

Health hazard
o Possible leak of the liquid nitrogen and
o Extremely High magnetic field that would probably require a buffer zone
to protect mine personnel and wildlife
8.2.3 Connection

A SMES unit could be installed in much the same way as the current diesel standby
generators at the BPC main switchyard to Jwaneng mine. The function would be almost
the same as well, except the SMES would be capable of faster switch over times (unlike
with the generators which are manually started), it would compensate to the entire mine
supply grid (the current generators only supply critical processes) but with the setback of
higher capital costs.

20
http://en.wikipedia.org/wiki/SMES, accessed 31 August 2006
21
http://www.parcon.uci.edu/OLD_WEBSITE/paper/eeenergy.htm, accessed 7 September 2006
_______________________________________________________________________

Figure 8.4 SMES Connection

Figure 8.4 shows a possible connection of the SMES unit feeding on to busbars A at the
main switchyard. Only critical loads will be left online when the SMES unit is operating
to ensure a longer operating time and to avoid overloading.

The South African supply utility has an SMES installed at the South Africa Pulp and
Paper Industry (SAPPI) paper mill located in Stanger, South Africa mainly for the
purpose of eradicating the bad effects of voltage dips.

The SMES has been successful in 16 months of use, giving 100% protection against 139
sags, half or more of which previously would have shut down the plant.
22

8.3 UPS
UPS may be used to protect low power sensitive microprocessor based equipment such as
computers (including mail/web servers), PLCs, meters and SCADA systems against
minor (both magnitude and duration) power dips.

UPS can be connected to a network as Standby (offline), Delta conversion online, Dual
conversion online or Ferro-resonant. In standby mode the UPS may drain the battery and
switch off even when line voltage is still present whereas the dual and the delta

22
http://findarticles.com/p/articles/mi_qa3739/is_199903/ai_n8850296 accessed 7 November 2006
_______________________________________________________________________
conversion online are not very efficient. Connection under Line Interactive mode is the
most efficient.
23 below
8.3.1 Principle of Operation

Line interactive UPS units are designed so that the inverter is always connected to the
output of the UPS. When line power is present, the inverter operates in reverse to charge
the battery. When utility power fails, the UPS reverses the power flow from the inverter
and provides power to the load. This design provides better filtering than a standby unit
because the inverter is always connected to the load. Line interactive units typically will
incorporate an automatic voltage regulator. AVR allows the UPS to effectively step-up or
step-down the incoming line voltage without switching to battery power. This allows the
UPS to correct most long term over-voltages or under-voltages without draining the
batteries. Another advantage is that it reduces the number of transfers to battery which
extends the lifetime of the batteries.

Line-interactive UPS units are the most common design for units in the 0.5 kVA to 5
kVA range. They are typically used in small server environments.
23
The following are
some of the factors to consider when choosing a UPS;
VA and wattage ratings - type of load and maximum
Runtime amount of load and battery
Battery replacement
8.3.2 Case Study - Synchrotron Radiation Source

The Synchrotron Radiation Source (SRS) is the UKs only dedicated source of high
energy synchrotron radiation. It is required to run 24 hours a day. At the heart of the
system are two 300kVA UPS of the continuous on-line type. The UPS allows a
maximum output current of 417 Amps. If however the load had a unity power factor, this
would have de-rated the UPS to a maximum current of 334 Amps. To optimize the size

23
http://en.wikipedia.org/wiki/Uninterruptible_power_supply, accessed 17 August 2006
_______________________________________________________________________
of UPS it was necessary to balance the load
wherever possible and to use the highest
phase current measured.
24
This system is
shown in Figure 8.5

When the commercial supply is interrupted,
the internal batteries sustain the power to the
inverter until either the mains returns or the
Diesel generator operates. If the Diesel fails
to start then the mains must return within 6
minutes on maximum load before UPS
shutdown occurs. In the event of this happening the battery contactor will be opened and
a clean break achieved.
24

Figure 8.6
8.3.3 Case Study - Uses in the mine

Present use of UPS within Jwaneng Mine is for protection of instrumentation for control
electronics including PLCs, PCs, Power meters and other sensitive small power
electronic equipment. The nameplate ratings and the connection of the UPS units
installed at the DMS in the MTP are as shown in the table and Figure 8.7.

24
S A Griffiths, D E Poole, AN UNINTERRUPTIBLE POWER SUPPLY FOR THE SRS, CLRC
Daresbury Laboratory

Figure 8.5
_______________________________________________________________________
Table 8.0 - Nameplate Ratings of UPS at MTP DMS
INPUT 3 Phase ac OUTPUT 3 Phase ac
Voltage (V) 380 15% 220 1%
Power (kVA) 12.4 10
Frequency (Hz) 50 50
Current (A) 19 45

The bypass switch shown in Figure 8.7 will disconnect the supply to allow the IPDB and
the rectifier to be supplied by the UPS in the event of a voltage dip or surge. The UPS
will therefore compensate voltage in the event of a dip as long as the magnitude of the
dip is not below 15% of nominal voltage as shown in Table 8.0. If the power dip is severe
and the magnitude of the incoming voltage falls below 15% of nominal then the UPS trip
and hence cut off supply to its connected loads and a manual switch over has to be
carried out once all faults have been cleared.
UPS requires regular maintenance of its
battery packs but every time this is done
its loads are left vulnerable directly
connected to the supply. This could
however be ratified by connection in what
can be termed the master and slave system
using two similar UPS units such that one
will be on standby to supply the load when
the other unit fails or is on maintenance.

A larger UPS could be used to keep contactors closed in the event of short, low
magnitude power dips which would not cause any damage on the protected loads
especially on the most critical ones. The contactors will therefore stay closed for a
predefined time and dip magnitude as long as the connected drives are still functioning
normally until the voltage stabilizes to nominal.

Figure 8.7
_______________________________________________________________________
However with a larger unit and the current diesel generators that is at the main
switchyard and connection could be made for the most critical processes in the same way
as shown in Figure 8.5 and 8.6 above. This setup could help critical loads ride
uninterrupted through short power dips.

UPS can however cause a power quality problem referred to as flat
topping as shown in Figure 8.8. This normally occurs with
transformer-based UPS units that overload in current.
Standby UPS systems can also cause a frequency shit in the voltage
sine wave as shown in Figure 8.9 at the time of switching on.

8.4 Flywheel Energy Storage
FES works by accelerating a rotor to a very high speed and maintaining the energy in the
system as inertial energy. The rotors normally operate at 4000 RPM or less. Quick
charging is done in less than 15 minutes. Long lifetimes of most flywheels, plus high
energy densities and large maximum power outputs are positive attributes [Appendix
A8]. The energy efficiency of flywheels can be as high as 90%. Since FES can store and
release power quickly, they have found a niche providing pulsed power.
25
Energy is
stored in the rotor in proportion to its momentum, but the square of the angular
momentum. The kinetic energy stored in a rotating flywheel is:

Where
is the angular velocity, and
I is the moment of inertia of the mass about the centre of rotation. (dependant on
the shape)

25
http://en.wikipedia.org/wiki/Flywheel_energy_storage, accessed 28 September 2006
Figure 8.8
Figure 8.9
_______________________________________________________________________

Figure 8.9a

The dc-voltage output of the motor/generator set has to be conditioned by a typical power
conversion system to interface with the external supply and load.
8.4.1 Cost Analysis

American Flywheel Systems Inc. has estimated the direct cost (excluding overheads) of a
1000kWh/l00kW flywheel system at $200/kWh equivalent to BWP 1,285.56
26
on 3
October 2006. This estimate includes the cost of the rotor, shaft structure,
motor/generator, bearing, cooling, vacuum assist, containment, and system
assembly/installation.
27

Advantages: Flywheels store energy very efficiently (high turn-around
efficiency) and have the potential for very high specific power compared
with batteries. Flywheels have very high output potential and relatively

26
27
Abbas Akhil, Shiva, Swaminathan, Rajat K. Sen, Cost Analysis of Energy Storage Systems
for Electric Utility Applications, Sandia Report, February 1997
_______________________________________________________________________
long life. Flywheels are relatively unaffected by ambient temperature
extremes.
28

Disadvantages: Current flywheels have low specific energy. There are
safety concerns associated with flywheels due to their high speed rotor and
the possibility of it breaking loose and releasing all of its energy in an
uncontrolled manner. Flywheels are a less mature technology than
chemical batteries, and the current cost is too high to make them
competitive in the market
28 above

8.5 Power Conversion System
8.5.1 Proposed System
Figure 8.9b below shows one possible way of connecting the ES to a critical load. The
control is divided into two loops. The inner loop provides high speed regulation and may
contain voltage control circuitry. The outer loop is slower and may just be a time clock
that schedules the charge and discharge times so as to coincide with the system peak and
low load periods respectively

28
http://www.upei.ca/~physics/p261/projects/flywheel1/flywheel1.htm accessed 6 November 2006
_______________________________________________________________________

Figure 8.9b
8.5.2 Cost of the PCS
The average cost of a PCS is usually about US $300/kW. The cost of the PCS installed
for the BES project at PREPA shown in Table 8.1 was US$ 5 713 000 and uses self
commutated GTOs which are capable of 4-quadrant operation
8.6 Case Study Cost Breakdown of SMES and BES
The following table shows existing plants that use SMES and BES showing the cost in
US$.

_______________________________________________________________________
Table 8.1 Cost Comparison of SMES and BES
Project/Product Description of System $/kW $/kWh 000s of $
Prepa 20MW, 40MWh BES 1102 1574 22042
Anchorage
Municipal L&P
30MVA, 375kWh SMES 1467 117333 44000
Source: Abbas Akhil, Shiva, Swaminathan, Rajat K. Sen, Cost Analysis of Energy Storage
Systems for Electric Utility Applications, Sandia Report, February 1997

For Jwaneng mine average demand was 32.34MW [Appendix A10] in the period from
January to October with a peak at 34.52MW.
_______________________________________________________________________
9 Smoothing out Voltage Profile
Discussed herein is the use of switches to successfully transfer load to an alternate supply
with SSTS or change taps on a transformer by SETC during a voltage dip. Also discussed
is the SVC which provides continuous reactive power compensation. This chapter
suggests a point a connection on the mines electrical reticulation system for both the
SSTS and SVC.
9.1 SSTS - The Solid State Transfer Switch
The SSTS essentially consists of a pair of thyristor switch devices. However, a thyristor
is not a pure conductor and raises some issues in terms of power loss and cooling. In a
conventional SSTS, line current flows in the thyristors continuously, causing a great deal
of power loss and element heating during normal operation. As a result, relatively large
cooling equipment is required which imposes additional operating costs on the user in
order to maintain thyristor cooling. It also results in reduced efficiency and lower. The
conventional SSTS is capable of transferring the load to an alternate supply in 4ms (38kV
phase, 1200A)
29

9.1.1 The Hybrid SSTS
The hybrid switch device (Figure 9.1)
essentially consists of a pair of thyristors
and a high-speed mechanical parallel
switch which has an opening time
capability of less than 1 (One)
millisecond.
30

The SSTS employs a secondary

29
POHJANHEIMO P., A Probabilistic Method for Comprehensive Voltage Sag Management in Power
Distribution Systems, Doctoral thesis, Helsinki University of Technology, 2003
30
MASATOSHI TAKEDA, PH.D. HIROSHI YAMAMOTO GREGORY F. REED, PH.D. TOMOHIKO
ARITSUKA ISAO KAMIYAMA, Development of a Novel Hybrid Switch Device and Application to a
Solid State Transfer Switch
Figure 9.1
_______________________________________________________________________
independent feeder with sufficient capacity in parallel with a primary line that the load is
connected to. When auto reclose is initiated on the primary due to a fault the SSTS
immediately transfers the sensitive load to the secondary supply within milliseconds.
31

The SSTS can take about 0.4ms to switch over with a current of 750A. The time it takes
to switch between the PS and the TH is as shown in the Figure 9.2.

Figure 9.2
9.1.2 Connection

With the introduction of the Morupule-
Thamaga 220kV line in December 2006
as shown in Figure 9.3, SSTS could be
used with the existing lines on the
Thamaga-Jwaneng transmission such
that only one line transmitting at 220kV
(and capable of 40MW) is used at any
given time and the other is taken as a standby
supply.

This arrangement has to be negotiated with the supply utility to see if the current lines are
capable of such a revamp. Installation is at the discretion of the supply utility and the
mine should not incur any charges whatsoever.

31
J. D. MASTERS, Dowding Reynard & Associates (Pty) Ltd, Voltage Dip study at Jwaneng Mine-
addendum, 13 March 1997,
Figure 9.3
_______________________________________________________________________

Figure 9.4 Figure 9.5
SSTS generally requires the following;
Two feeders from different substations (or even transformers on same line)
Spare distribution capacity in the backup feeder
Spare distribution capacity in the substation
Reliable transmission with good power quality

One major disadvantage of this scheme however is that it reduces the contingency plan of
the supply of having more than one line supplying a load such that one is left online if
one goes faulty. Having the SSTS as close as possible to the mines main switchyard
would eliminate this problem (Any transmission lines that go beyond the mine should be
connected before the SSTS as illustrated in Figure 9.4). Village 1 & 2 transmission lines
on the diagram refer to the 2 Jwaneng Township 33kV lines.

Another main factor to consider is that it should be insured that the alternate line (supply)
is not at all affected by disturbances in the primary supply. However if the grid is strong
enough it may be adequate to install the SSTS such that it transfers the load from one
_______________________________________________________________________
transformer to the other as shown in Figure 9.5. This arrangement will compensate for all
dips whose cause was on the MV feeders. The setup will be rendered useless for any
faults occurring on the HV side (before either one of the transformers).

This setup is applicable at the MTP DMS 2MVA Transformers.
9.2 SETC - Static Electronic Tap Changer
It is often useful to have a number of taps on power
transformers such that the secondary voltage can be varied
accordingly. More often than not these transformer taps are
manually set and left at a certain tap where the nominal
secondary voltage will be defined by switch S as shown in
Figure 9.6 The transformer T4 at Jwaneng Mines main
switchyard is set on an appropriate tap manually such that the
power generated by the standby diesel generated can be
correctly synchronized to the grid to match the supply utility
(BPC) voltage. The static electronic tap changer can be used on the transformers T1 and
T2 such that secondary voltage is closely monitored and as soon as a dip from nominal by
more than 10% is seen then the taps are changed automatically to increase the secondary
voltage back to nominal until a time when the cause of the dip (fault) has been cleared.

However allowance should be made for some devices such that an expected voltage drop
should not initiate operation of the SETC prematurely. For example if starting of an
induction motor is expected to drop the voltage and recover within 100ms without
affecting any equipment in the vicinity then the SETC can operate only if the voltage
drop goes below 10% (or a predefined limit) for more than 100ms provided this is also
within the required grading margin for protection and discrimination. This is illustrated as
TD (Time Delay) in the diagram below; (LTC is load tap changer, same as SETC)

Figure 9.6
_______________________________________________________________________

Figure 9.7
The switch employed by the SETC uses IGBT which can have a switch over time of
about 300 ns
32

9.3 SVC - Static VAr Compensator
A static VAr compensator (or SVC) is an
electrical device for providing fast-acting
reactive power compensation on high-voltage
electricity transmission networks.
Figure 9.8 shows a simplified single-line
diagram of a Static VAr compensator
featuring one thyristor-controlled reactor and
three mechanically switched capacitors.
9.3.1 Principle of Operation of the SVC

32
GOOGLE CACHE, http://64.233.183.104/search?q=cache:t-
Ff7OuPhW0J:www.members.lycos.nl/caspoceducation/0899.pdf+static+electronic+tap+changer&hl=en&g
l=uk&ct=clnk&cd=14, accessed 18 September 2006
Figure 9.8
_______________________________________________________________________

Figure 9.9a

Typically an SVC comprises a bank of individually switched capacitors in conjunction
with a thyristor-controlled air- or iron-cored reactor. By means of phase angle modulation
switched by the thyristors, the reactor may be variably switched into the circuit, and so
provide a continuously variable MVAr injection (or absorption) to the electrical network.

Coarse voltage control is provided by the capacitors; the thyristor-controlled reactor is to
provide smooth control - Figure 9.9a. Chopping the reactor into the circuit in this manner
injects undesirable odd-order harmonics, and so banks of high-power filters are usually
provided to smooth the waveform. Since the filters themselves are capacitive, they also
contribute to the net MVAr injection. Other arrangements such as a thyristor-switched
reactor and thyristor-switched capacitors are also practical. Voltage regulation is
provided by means of a closed-loop controller. Remote supervisor control and manual
adjustment of the voltage set-point are both possible Figure 9.9a.

The three phase SVC unit is a continuously variable reactive power compensator that
connects directly to the utility grid, and operates in a stand alone mode without the need
for any external power sources such as a battery bank or diesel generator. It can feed
leading or lagging currents to compensate for the reactive currents generated by such
appliances as grid feeding motors, generators, wind turbines or any other device having a
reactive power component. The SVC can operate in both quadrants and is not limited to
compensating the inductive reactive component of motors or generators.
33 below

_______________________________________________________________________

The SVC by Advanced Energy Systems uses their current control technology for power
conversion, and draws only a small amount of real power from the grid and outputs either
a positive or negative reactive power. The SVC has its own micro-controller that
performs low-level control and monitoring of the system, and implemented within the
micro-controller is AES's patented "Ramp time" current control algorithm. This
algorithm is used to control the power electronics of the current control mechanism.
33
below

Some of the reasons for incorporating SVC in transmission and distribution systems
include:
To stabilize voltage in weak systems.
To reduce transmission losses.
To increase the transmission capacity, thus delaying the need for new lines.
To increase the transient stability limit.
To increase damping of small disturbances.
To improve voltage control and stability.
To damp power swings.
33

Series compensation is an economical method of improving the power transmission
capability of the lines. Series capacitor banks are useful because they;
Increase power transfer capability,
Improve system stability,
Reduce system losses,
Improve the voltage profile of lines,
Optimize current sharing between parallel lines.

33
http://www.aesltd.com.au/whatwedo/docs/svc_over.htm - 1 September 2006
_______________________________________________________________________
The cost of a series capacitor bank is about 10% of the cost of a new transmission line.
Thus, the payback time for a series capacitor bank investment is typically only a few
years.
34

The SVC can be operated in two different modes either in voltage regulation mode (the
voltage is regulated within limits) or in VAr control mode (the SVC susceptance is kept
constant). For the protection against dips the voltage regulation mode would be the
preferred mode of operation.

The main advantage of SVCs over simple mechanically-switched compensation schemes
is their near-instantaneous response to changes in the system voltage. For this reason they
are often operated at close to their zero-point in order to maximize the MVAr reserves
they can rapidly provide when required. SVCs are in general cheaper and require lower
maintenance than dynamic compensation schemes such as synchronous compensators.
35

The SVC can also aids in actively correcting the power factor at the mine to the desired
level.
9.3.3 Connection

Ideally the best point for connection of an SVC is either on
the 132kV Thamaga to Jwaneng or the 220kV Segoditshane
to Thamaga transmission lines. This is where most of the
faults that have led to voltage dips experienced by the mine
originate. It is therefore vital that talks are held with the
supply utility on the quality of the power they supply to
Jwaneng mine and consideration of the supply contract has
to be made such that they can be asked to implement the
SVC on the transmission lines. This would be the best
approach as a solution to the problem of power dips as

34
http://www.power-technology.com/contractors/tandd/nokian/ - accessed 28 August 2006
35
"http://en.wikipedia.org/wiki/Static_VAr_compensator" accessed 11 August 2006

Figure 9.9b
_______________________________________________________________________
it means the mine will not incur any costs whatsoever on the installation process.

However as there is an ongoing research on optimization of the mines power factor,
SVC could also be considered as one possible solution killing two birds with one stone.
This would basically call for re-using the capacitor banks already in place on the network
at the Northern well fields but adding on the extra functionality to make an SVC (See
Figure 9.8).

_______________________________________________________________________
10 General Power Quality Mitigation
Power Quality issues are mentioned in Section 1.2.1 as being separate entities. On the
other hand these issues can directly affect the Quality of Supply and therefore if not
attended to they can increase the occurrence of voltage dips. In most cases resolving one
power quality issue directly impacts on the other issues thereby optimizing general power
quality. Some power quality aspects are thereby briefly discussed in this chapter. The last
part proposes a new way of recording of voltage dips to improve on the methods
mentioned in section 2.
10.1 Ferranti Effects
A long transmission line draws a substantial quantity of charging current. If such a line is
open circuited or very lightly loaded at the receiving end, the voltage at receiving end
may become greater than voltage at sending end. This is known as Ferranti Effect and is
due to the voltage drop across the line inductance (due to charging current) being in
phase with the sending end voltages. Therefore both capacitance and inductance are
responsible to produce this phenomenon. The capacitance (and charging current) is
negligible in short line but significant in medium line and appreciable in long line.
Therefore this phenomenon occurs in medium and long lines.
36

The SETC mentioned in Section 9.2 can be used on the transformers at the mines main
switchyard on the 132/33kV and the 132/6.6kV to avoid this effect. During maintenance
when large loads have to be switched off it should be done in a systematic manner and
the supply utility should be informed so that they can regulate their system accordingly.
10.2 Blackouts (Interruptions)
The causes of blackouts are sometimes similar to those that cause voltage dips. To ensure
that some of these unwanted interruptions are avoided generation should be closely

36
http://www.ku.edu.np/ee/rb/Handouts_COEG301&303/Ferranti%20Effect.pdf, accessed 14 August 2006
_______________________________________________________________________
matched to demand so as to avoid overloading the transmission network. This requires
close cooperation of both the supply utility and the mine optimising distribution and load
respectively. The supply utility should also arrange for a systematic and controlled load
shedding when there is a fault such that mines supply can be sustained at optimal levels
at all times. The mine should ensure that they have a reliable standby supply with spare
distribution capacity.
10.3 Surges (Swells)
This is mostly caused by lightning and can sometimes occur after a voltage dip when the
system tries to recover under very low load. Surge arresters can be used on light loads to
avoid damage. UPS generally protects against this as well because it smoothens out its
output. For larger loads protection settings should be set to trip and isolate appropriately.
10.4 Over voltages & under voltages
The normal operating voltage at Jwaneng Mine is about 105% on the 6.6kV lines and
about 110% on the 525V network. The higher percentage that nominal (10% is the upper
bound of optimal supply) may be caused by miscalculation on transformer tap settings.
10.5 Harmonics & Interharmonics
These are mainly caused by static frequency converters, cyclo converters, induction
motors and arcing devices. Interharmonics have the effect of inducing visual flicker on
display units. Power line carrier signals are also referred to as interharmonics.

Mitigation of harmonics by active filters or a tuned filter as mentioned in Section 7.4 can
prove quite effective
10.6 Notches
This is caused mainly by power electronics devices when the current is commutated from
one phase to another during the momentary short circuit between two phases. Frequency
_______________________________________________________________________
components associated with notching can be very high and measuring with harmonic
analysis equipment may be very difficult.

Similarly to mitigation of harmonics, notching can be avoided by using active power
filters or tuned filters.
10.7 Voltage Fluctuations (Flicker)
There is usually a visible impact of voltage fluctuations on lamps as they flicker. One of
the main causes is arc furnaces. This particular problem has not been reported as a cause
of head feed delays at Jwaneng mine probably because the installed DPIs and UPS help
in minimising voltage fluctuations.
10.8 Recording & Reporting Of Power Dips (Proposed)
Power dips need to be recorded and carefully documented in order to establish their
causes, effects on the mine and ways to mitigate against them.

This part hereby outlines a procedure which is a guideline in order to record power dips.
The procedure applies to all Engineers, Planning Foremen, Engineering Foremen,
Operation Foremen, CCR Operators, Supervisors and all to whom power dips is a
problem who are tasked with ensuring that accurate and correct recording is done. The
revised procedure was approved by the mine personnel and has been posted on the
intranet so that it can be used whenever there is a power dip.
10.8.1 Procedure
Whenever a power dip occurs in any plant area the information should be recorded on the
form provided in [Appendix A9]

The information should be forwarded to the Section Engineers both at Electrical Services
and MTP by fax or e-mail at least within twenty-four (24) hours of the power dip and
should conform to the following notes;
_______________________________________________________________________

i. Details of Occurrence must be cross referenced to CCR reports
ii. Duration of delays is reported by CCR and should include all production
downtime (including start up time of the plant)
iii. Comment on extent of production loss should be obtained from TREATMENT
and should include tons/hour treated before onset of dip, FeSi loss etc.
iv. If cause of dip is not clearly known then any electrical fault seen on the line (or
plant) at the time of dip can be recorded as probable cause
v. NCC (or protection engineers at BPC) should be contacted for their input (if the
dip registered on their system) any transmission faults should also be noted
10.8.2 Follow up Action/ Feedback
Follow-up action is the most important part of this recording procedure and should be
updated latest by the following day and be reported at the morning production meetings.
Section Engineer at Electrical Services should update form for note (v) below;

i. Dip magnitude and duration can be obtained from BPC power meters at the main
switchyard (NOTE: BPC downloads data every month) if the dip registered on the
transmission network otherwise voltage profiles downloaded from the mine yards
(substations) can be used.
ii. Fault type should also state which protection operated e.g. Current differential, 3
trip and ARC/Lock Out
iii. Comments on what NCC is doing about the problem should be registered (for
faults on the transmission network)
iv. Total load shed should be cross checked with BPC and follow up can be done
with voltage (power) profiles
v. Treatment Unit should also state if they have done anything to resolve the
problem and where in the plant they are most severely affected.
10.8.3 Responsibilities
It is the responsibility of Section Engineers (EE1 and EE2) to ensure that they follow up
the power dip form immediately after there was a power dip. Engineering foremen and
_______________________________________________________________________
Operation foremen should ensure that their respective parts are filled and forward the
form to the appropriate recipient well on time as stated in section 10.8.1. EE1 and
Electrical Services should ensure that the BPC part is filled up.
_______________________________________________________________________
11 Discussion
This chapter analyses the research presented in this report and report phase 1 and
thereby concludes Analysis of Voltage dips for Jwaneng Mine and proposes future work
on this field in the quest to exterminate the effects of dips.
11.1 Project Objective Review
The main objectives for the research of this project were to;
Identify causes of voltage dips in the Mine
Investigate possible solutions to the problem

The objectives for this project have been successfully achieved, the causes,
characteristics and effects of voltage dips on different operations within Jwaneng mine
were established the bulk of which was presented in report Phase 1 and several possible
solutions were recommended in this report.
11.2 Conclusions
It was reported in the report for this research phase 1 that the recording and reporting of
power dips is inadequate but new light into the research is that there is a balanced score
card being carefully updated and both magnitude and duration of any dips that register at
the main switchyard can be recorded. However this information is not being made
available to electrical workshops. Power Meter readings should be put on the internal
servers such that Electrical Workshop foremen and Section Engineers at various parts of
the mine can monitor general power quality.

Power Factor Correction capacitors and UPS units may sometimes contribute to
Harmonics hence ways to mitigate against this should be investigated.

_______________________________________________________________________
There is no general transparency of information that is usually dished out to the mine. For
the mine to validate the quality of supply they would have to use the supply utilitys
records which can be biased. Contracted companies do not usually share with the mine
what they call their trade secrets. Some examples are the two following companies;

Netlab on protection and discrimination settings
o The company comes to the mine, does their feasibility studies, and
recommends new settings which they put up and more often that not the
drives still trip after they leave.
Switching Systems on DPI settings
o The time settings for the DPI are not set by personnel on the site but these
can not be left at only one setting when the load changes or even when the
power factor changes.

It was indicated in phase 1 report that the mine incurs no charges for a bad power factor,
however, even though this may be true, new light has been shed into this research that the
mine is contractually bound by the supply utility to keep its power factor above 0.85 as
stated in the mine quarries act.

For the DPI currently installed within the mine, MTP and RP have expressed satisfaction
on reliability but Red Area plant still has problems with protected loads tripping.

Comparison of the balanced score card from 2005 with the one for 2006 shows that no
significant improvement has been made in minimising head feed delays due to power
dips or cutting down on the frequency of their occurrence.

More often than not SMES is usually discarded as being way too expensive for the mine
environment solid evidence needs to be brought up to back this up and compare the
revenue losses that may be encountered to the capital and maintenance costs of the
SMES. The same applies to the other Energy storage devices. The mine should request
quotations for each of these.
_______________________________________________________________________
11.3 Future work
Asses how introduction of the 220kV transmission line from Morupule affected the
system does it improve the fault level rating significantly and does this directly reduce
the occurrence of dips that the mine experiences?

Commissioning of Mmamabule coal plant proposed for 2010 how will this impact on
the transmission system?

Feedback should be sought on the improvement on the recording procedure as suggested
in this report.

Analysis of reliability and effectiveness of the chosen power dip mitigating solution by
the mine

The list of critical loads mentioned in chapter 8 should be updated to reflect the current
scenario at all times.

There is a new plant to be built to replace the current MTP, Load may change
considerably. A further investigation should be carried out to see how this is going to
affect the quality of supply.

_______________________________________________________________________
References

[1] www.powerstandards.com/tutorials/sagsource.htm, accessed 14 June 2006
[2] http://www.power-innovations.com/about_power/dyk.html accessed 6 November
2006
[3] http://www.pur.com/pubs/1251.cfm accessed 7 November 2006
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st
December 1979
[5] DEBSWANA DIAMOND COMPANY (Pty) Ltd, Jwaneng Mine, Engineering
Electrical Services Standard Procedure, Procedure No: EE-E1-06, Critical Loads
to be supplied from the Power Station Diesel Generators during a BPC Power
Supply Failure, Revision 1, 7 June 1996
[6] G.J COETZEE, Power Quality paper #1 Causes of voltage dips & resulting
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[8] www.fortressresistors.com/neutral_earthing.htm, accessed 11-Aug-06
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[10] NEIL JEFFREY, Dynamic Range Requirements of Capacitor VT Sensors
for Protection Systems, SURE Engineering CC, 23 March, 1999
_______________________________________________________________________
[11] JEFF ROBERTS, DR. HECTOR J. ALTUVE, AND DR. DAQING HOU,
Review of Ground Fault Protection Methods For Grounded, Ungrounded, and
Compensated Distribution Systems, Schweitzer Engineering Laboratories, Inc.
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Analysis of Energy Storage Systems for Electric Utility Applications, February
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[13] http://www.xe.com/ucc/convert.cgi, accessed 3 October 2006
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September 2006
Analysis of Energy Storage Systems for Electric Utility Applications, Sandia
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.pdf, accessed 14 August 2006
_______________________________________________________________________
APPENDIX A1 Effects of Capacitance

All Three Phases

Phase to Phase

Single Phase

_______________________________________________________________________
APPENDIX A2 Effects of Load

All Three Phases

Phase to Phase

Single Phase

_______________________________________________________________________
Appendix A3 - Delays due to Dips 2005

IP4 : Headfeed delay hours due to power interuptions & dips
5.0
0.5
3.6
2.93
1.8
0.0 0.0 0.0 0.0
6.0
0.0
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
J
a
n
-
0
5
F
e
b
-
0
5
M
a
r
-
0
5
A
p
r
-
0
5
M
a
y
-
0
5
J
u
n
-
0
5
J
u
l-
0
5
A
u
g
-
0
5
S
e
p
-
0
5
O
c
t-
0
5
N
o
v
-
0
5
D
e
c
-
0
5
Actual- Total EXTERNAL INTERNAL Threshold Target Stretch Target Baseline Other

IP5 : Reduction of Power Dips - Frequency of dips affecting plants
7.0
2.0
10.0
5.0 5
0 0 0 0
5
0
0.0
2.0
4.0
6.0
8.0
10.0
12.0
J
a
n
-
0
5
F
e
b
-
0
5
M
a
r
-
0
5
A
p
r
-
0
5
M
a
y
-
0
5
J
u
n
-
0
5
J
u
l-
0
5
A
u
g
-
0
5
S
e
p
-
0
5
O
c
t-
0
5
N
o
v
-
0
5
D
e
c
-
0
5
Actual EXTERNAL INTERNAL Threshold Target Stretch Target Baseline Other

Objectives - To clearly identify external and internal dips especially after the
commissioning of the NER whose performance must be measured and compared to last
year when there was no NER.
_______________________________________________________________________

Appendix A4 - Utilities Failures - Red Area

DATE DELAY(min) STM MACHINE CODE DELAY REPORT
12/20/05 25 PNEUMO AJX0305
POWER DIP ON THE COMPRESSOR
AND PNEUMO DRYER
01/08/06 67 PNEUMO AJX0320/0305
POWER DIP ON THE PNEUMO
BLOWERS AND THE PERMROLLS.
01/09/06 45 PNEUMO
POWER DIP (AFFECTED PNEUMO
BLOWER, AND SCRUBBER)
01/09/06 37 PNEUMO
PLANT START UP AND RAISING
PNEUMO TEMPERATURES
174
01/22/06 30 PNEUMO POWER DIP
02/04/06 40 PNEUMO
START UP AND RAISING SOUTH
EAST PNEUMO TEMPERATURE
AFTER POWER DIP
02/08/06 14 PNEUMO SE
RAISING PNEUMO LINE TEMP AFTER
POWER DIP
02/11/06 20 PNEUMO
PNEUMO
BLOWER POWER DIP
02/12/06 51 PNEUMO
POWER DIP (JC NO'S R00767941 AND
R00767946)
02/03/06 57 PNEUMO AJX2801
POWER FAILURE .( FEED PREP
SECTION) R00765904
02/14/06 94 PNEUMO AJX0305
POWER DIP ( AFFECTED THE
PNEUMO , SICON AND COMPRESSOR
) .
412
02/17/06 40 PNEUMO AJX0305 POWER DIP. ( R00769371)
02/20/06 57 PNEUMO AJX0305
POWER DIP TRIPPING THE SE
PNEUMO.
02/23/06 25 PNEUMO ALX LT 0801
DUST SCRUBBER RAW WATER
STORAGE TANK LEVEL LOW.
02/16/06 41 PNEUMO AJX 0305 POWER DIP
02/22/06 18 PNEUMO AJX 0305
RAISING SE PNEUMO
TEMPERATURE AFTER POWER DIP
02/23/06 29 PNEUMO AJX 0305 RAISING PNEUMO TEMPERATURE
03/07/06 68 PNEUMO AJX0305
POWER DIP. ( FEED PREP SECTION)
R00773141
356
03/18/06 80 PNEUMO AJX0305 POWER DIP
03/19/06 27 PNEUMO AJX0305 POWER DIP. ( R00775898)
_______________________________________________________________________
04/09/06 66 PNEUMO AJX0305 Power dip
307
06/01/06 43 PNEUMO AJX8001
GREEN AREA RAW WATER PUMP
TRIPPED.
43
84
08/01/06 30 PNEUMO AJX 0305 POWER DIP AND START UP
30
09/11/06 16 PNEUMO AJX 0320 NW Pneumo tripped.
09/07/06 61 PNEUMO AJX 0305/0320
POWER DIP (PNEUMO BLOWERS
TRIPPED)
09/07/06 38 PNEUMO AJX 2501
RAISNG PNEUMO TEMP AFTER
POWER DIP
115
37

Total
Hours 24

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_______________________________________________________________________
Appendix A6 Sag Generator Costs @ PSL

_______________________________________________________________________

Appendix A7 Earthing For Different Sections

1. EARTHING
The Contractor, in conjunction with the Engineers site representative is to propose a
scheme that complies with the requirement set out herein, mark up routing and racking
drawing and submit for the project Engineers approval.

2. Earthing of Racking
2.1.1. Each racking route shall have a minimum of one 70mm
2
bare copper earth
run along its route from the substation earth bar. The 70mm
2
bare copper
earth shall form a ring such that both ends of the ring are connected to the
substation earth bar.
2.1.2. Racking shall be bonded to the 70mm
2
bare copper earth ring by means of
a 35mm
2
bare copper earth wire and purpose made earth clip at intervals not
exceeding twelve metres. Further, the 70mm
2
bare copper earth shall be
bonded to the steel structure at intervals not exceeding twelve metres. This
may be done by means of 35mm
2
copper wire being bonded to racking
support steel bolts where it is bolted onto the building or structure.
2.1.3. Racking between substations is to be bonded in the same fashion as
described above except that the ring shall be from one substation earth bar to
the other. Earths required to be run with M.V. and H.T. feeder cables may
be used for this purpose

3. Earthing of Substations
3.1.1. Each substation is to have an earth bar installed in its cable basement or
trench fixed to the side wall.
3.1.2. The substation earth bar is to be connected to the substation earth bar from
which it is fed by means of either a 70mm
2
bare copper or green PVC
_______________________________________________________________________
insulated earth. In the case of multiple feeds, one earth connection between
substations will suffice.
3.1.3. In substations where earth mats are installed, the earth bar is to be
connected to the earth mat by means of two 70mm
2
green PVC insulated
copper cables. This connection is to be to a separate earth bar which has a
removable link connecting it to the substation main earth bar.
3.1.4. Substation earth bars shall be of hard drawn copper, 50x6x1000mm
minimum pre-drilled and fitted with brass nuts, bolts, washers and spring
washers to facilitate all connections.
3.1.5. Substation earth bars when measured to true earth, shall not exceed 1
ohms

4. Earthing of Switchboards and M. C. C. s
4.1.1. Switchboards and M.C.C.s earth bars are to be connected to the
substation earth bar by means of two 70mm
2
bare copper conductors, one
from either end of the MCC or switchboards earth bar.

5. Earthing of Transformers
5.1.1. Solidly earthed neutral to earth conductors are to be the same size as phase
conductors but, in all cases, not less than 16mm
2
and connected from the
neutral terminal directly to the substation earth bar.
5.1.2. Solidly earthed neutral transformers shall have their tank earth connected
to the substation earth bar by the same size conductor as the neutral earth,
but in all cases, not less than 70mm
2
.
5.1.3. The neutral and tank earth connections may not be connected to each other
and to the substation earth bar by one set of conductors. However, an earth
bar may be established in the transformer bay, both the transformer tank and
the neutral connected to it and a connection from the transformer bay earth
bar to the substation earth bar made in conductors sizes as specified above.
5.1.4. Transformers installed in locations that are not in close proximity of
substations containing earth bars may require earth electrodes installed to
_______________________________________________________________________
provide a earthing connection of not more than 1 ohms to true earth.
5.1.5. Generally, on 525V transformers, Isoloc or resistive earth systems are
used. The details of the systems will vary for different applications and will
be described in the Project Specific documentation.

6. Earthing of Motors
6.1.1. All motors are to have a separate visible earth, equal in cross-sectional
area to the supply cable conductor, connected from the motor housing to the
70mm
2
racking earth ring. Further, a connection of the same cross sectional
area as the supply cable is to be made from the motor housing to the motor
base plate. These connections are to be made in such a manner that the
connection to the base plate will not be broken if the motor is removed.
6.1.2. In installations where the motor base plate is separate from the driven
machinery base plate a connection is to be made bonding the motor base
plate to the driven machinery with a 70mm
2
copper earth conductor.
6.1.3. H.V. and M.V. motors will, in addition to the above, be bonded to the
structural steel by means of a 70mm
2
copper earth conductor.

7. General
7.1.1. Earth conductors will be fixed to racking by means of U.V. resistant PVC
cable ties or other approved non magnetic means.
7.1.2. Earth conductors will not be run in metal conduit.
37

37
ANGLO AMERICAN CORPORATION OF SOUTH AFRICA LIMITED, FOR DEBSWANA
DIAMOND COMPANY (PTY) LTD, GENERAL SPECIFICATION, OR2-GS-220, ELECTRICAL
INSTALLATION GENERAL, 22/04/97
_______________________________________________________________________
Appendix A8 Flywheel vs. Battery Energy
38

38
Source: http://www.activepower.com/index.asp?pg=technology_flywheel_vs_battery,
accessed 28 September 2006
Active Power Clean Source Battery-based
Alternatives

Flywheel Technology VRLA (10year)
Life Span Design: 20+
Operational: since 1997
Design: 10 in float service
Operational: 3 to 6, typical
Discharge Cycles Unlimited for product life span 1000-2000 shallow
100-200 deep
Optimal Temp (C) -20 to +40 25
Maintenance Air filters: as req.
Oil Change: 12 mos.
Bearings: 30 mos.
Preventative maintenance: 3
to 6 mos.
Jar replacements: as req.
Predictability Self Diagnostics: standard
Monitoring software & cards:
optional
Requires battery monitoring
system
Footprint
(w/ service access
500kW =>
20 sq.ft.
500 kW =>
60-80 sq.ft.
"Green"
Technology
No environmental hazards HazMat disposal issues
Spill containment
Personnel safety
EPA regulations
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Analysis of Voltage dips
_______________________________________________________________________
Appendix A10 - Maximum Power Demand

IP5: MAXIMUM DEMAND
31.80
32.24
32.76
32.22
30.98
30.48
32.24
32.48
34.52
33.72
28
29
30
31
32
33
34
35
Internal External Actual Threshold Target Stretch Target

IP5: TOTAL MINE POWER CONSUMPTION IN MWh
17254
19306
17576
18879
17028
18738
19009 19004
20648
17987
15000
16000
17000
18000
19000
20000
21000
22000
23000
Actual Threshold Target

Voltage Dip

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