Foundation Coal 4100XPB, Shovel 10 P&H Centurion 750 Control System Upgrade. Presented by: P&H MinePro Services Gillette, Wyoming November 17, 2006

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1 Foundation Coal 4100XPB, Shovel 10 P&H Centurion 750 Control System Upgrade Presented by: P&H MinePro Services Gillette, Wyoming November 17, 2006

2 Overview Upgrade Packages Available Centurion / Upgrade Benefits Machines Upgraded to Date Foundation Coal, Centurion 750 Background Upgrade Goals Installation Results Questions

3 Centurion Upgrade Options Centurion Complete System Upgrade Centurion 750 Controller and I/O upgrade to digital system Centurion 500 Controller upgrade for digital systems

4 Centurion Full Upgrade Analog or Digital system replacement Complete System Upgrade Touch Screens Controller Smart I/O Drives Complete control cabinet

5 Centurion Upgrade Analog Layout Centurion Layout Panel View PLC GUI AC 800 PMD I/O Analog Drives GUI Smart I/O Drives

6 Centurion 750 Digital system control upgrade Touch Screens Controller Smart I/O Uses existing drives and control cabinet System converted to Centurion

7 Centurion 750 DDC Layout 750 Layout OAP PLC GUI AC 800 GUI Rem I/O AC 80 GUI Smart I/O Drives GUI Drives

8 Centurion 500 Digital system control upgrade Touch Screens Controller Uses existing drives, I/O, and control cabinet Cost effective upgrade with minimal investment of resources

9 Centurion 500 DDC Layout 500 Layout OAP PLC GUI AC 800 GUI Rem I/O AC 80 GUI PLC Drives GUI Drives Rem I/O

10 Centurion Based Upgrades Remote Communications Payload Measurement Automated Control

11 ShoveLink Remote Communications Remote shovel monitoring Faults, temps, recordings Data via OPC ShoveLink II Fleet management Web based SQL Server 2005 New diagnostic tools Supporting documentation

12 Payload Measurement Payload and Payload Plus Accuracy of 2% (error) Precision of 4% (repeatability) Calibration is very simple Reporting software SQL Server 2005 Remote downloads

13 Automated Control OptiDig II ABSS 3D Track Protection Avoids collisions Geometric model of shovel Predicts position/makes corrections Tested and running on 2100BLE and 4100A

14 Upgrade Benefits Performance Reduced Propel transfer time Reduced cycle times from Crowd extended speed range Coordinated motion speeds Opti-Dig II Integrated control of machine and drive Next generation automation options

15 Upgrade Benefits Diagnostics High level drive and controller diagnostics from the GUI Smart I/O with safer 24V DC control Smart I/O with internal diagnostics and health status from the GUI Simple and quick replacement of snap-in Smart I/O modules High bandwidth industry standard Profibus I/O network Improved noise immunity via fiber optic Profibus cabling

16 Upgrade Benefits New Functions Optional logarithmic joystick function, allows for smoother operation during small joystick movements. A brake set logic tracks time from brake solenoid off to pressure below 5 psi. A warning is logged if the time is greater then 500 ms. Soft shutdown logic added, allows controlled shutdowns of independent motions. Swing impact detection with optional alert sounded when impact is detected. Lube system faults will not trigger a immediate shutdown on the first occurrence; allows the operator to re-set the logic in an attempt to free a frozen/ lube line. After three failures or 15 minutes of non-lube operation, will cause trip. RPC bank hysteresis adjusted to allow for more aggressive switching of banks.

17 Centurion Shovels to Date Upgrades / 4100A / 4100XPB XPA / 2800XPB XPLR New shovel sales with Centurion as OE C / 4100XPC / 4100BOSS XPB XPC

18 Foundation-Centurion 750 Background 4100XPB, SN ES41111, commissioned in October ,000 hour MARC Agreement Centurion installed at approximately 33,000 hours started on June 26, 2006

19 Manpower/Timing Started outage June 26, 2006, duration of 11 days Retrofit was performed in conjunction with a major mechanical outage Centurion can be installed in 8 days Installation of hardware took 5 days 3 men on days 3 men on nights Testing and commissioning took 3 days 2 men on days

20 Upgrade Goals/KPI KPI s Demonstrate an improvement of.5 seconds in the dig cycle Demonstrate an improvement of 3 seconds (+/-.25 seconds) in propel transfer time each direction (6 seconds total) System-wide minimum availability is to be 88% for all hours of operation during the trial period All systems must pass an MSHA safety inspection for safe and efficient operation All electrical and control systems must demonstrate full integration and meet all electrical codes All components and equipment must be designed and installed for reasonable ease of access and maintenance

21 Project Install

22 Lower Works I/O (located on the lower works) Transfer Cabinet I/O Hoist I/O Lube Room I/O Converter I/O RPC I/O Front Machine House Wall I/O Control Cabinet I/O and Controller Operator Cab I/O Operator Cab Touch Screen Auxiliary I/O Control Room Touch Screen

23 Operator s Cab Hall effect Ergonomic Logarithmic New GUI s Independent New screens

24 Lower Works I/O (located on the lower works) Transfer Cabinet I/O Hoist I/O Lube Room I/O Converter I/O RPC I/O Front Machine House Wall I/O Control Cabinet I/O and Controller Operator Cab I/O Operator Cab Touch Screen Auxiliary I/O Control Room Touch Screen

25 Control Cabinet AB SLC ABB AC 80 ABB AC 800 Siemens Smart I/O

26 Control Cabinet ABB Drives Old GUI Fiber Optic Branching Unit Filter, Power Supply, Resolver Module

27 Lower Works I/O (located on the lower works) Transfer Cabinet I/O Hoist I/O Lube Room I/O Converter I/O RPC I/O Front Machine House Wall I/O Control Cabinet I/O and Controller Operator Cab I/O Operator Cab Touch Screen Auxiliary I/O Control Room Touch Screen

28 Auxiliary Cabinet Old Flex I/O Siemens Smart I/O

29 Lower Works I/O (located on the lower works) Transfer Cabinet I/O Hoist I/O Lube Room I/O Converter I/O RPC I/O Front Machine House Wall I/O Control Cabinet I/O and Controller Operator Cab I/O Operator Cab Touch Screen Auxiliary I/O Control Room Touch Screen

30 RPC Control Old Flex I/O Self Contained RPC Control PLC, Smart I/O, kvar xducer, firing board, sync xfmr, filter, power supply

31 Lower Works I/O (located on the lower works) Transfer Cabinet I/O Hoist I/O Lube Room I/O Converter I/O RPC I/O Front Machine House Wall I/O Control Cabinet I/O and Controller Operator Cab I/O Operator Cab Touch Screen Auxiliary I/O Control Room Touch Screen

32 Transfer Cabinet Flex I/O Smart I/O Filter & power supply

33 Lower Works I/O (located on the lower works) Transfer Cabinet I/O Hoist I/O Lube Room I/O Converter I/O RPC I/O Front Machine House Wall I/O Control Cabinet I/O and Controller Operator Cab I/O Operator Cab Touch Screen Auxiliary I/O Control Room Touch Screen

34 Converter Cabinet Old Flex I/O Smart I/O Filter & power supply

35 Lower Works I/O (located on the lower works) Transfer Cabinet I/O Hoist I/O Lube Room I/O Converter I/O RPC I/O Front Machine House Wall I/O Control Cabinet I/O and Controller Operator Cab I/O Operator Cab Touch Screen Auxiliary I/O Control Room Touch Screen

36 Hoist I/O Drop Added for more localized control and cabling Room for expansion for RTD s

37 Lower Works I/O (located on the lower works) Transfer Cabinet I/O Hoist I/O Lube Room I/O Converter I/O RPC I/O Front Machine House Wall I/O Control Cabinet I/O and Controller Operator Cab I/O Operator Cab Touch Screen Auxiliary I/O Control Room Touch Screen

38 Lube Room Old Flex I/O Smart I/O Filter & power supply

39 Lower Works I/O (located on the lower works) Transfer Cabinet I/O Hoist I/O Lube Room I/O Converter I/O RPC I/O Front Machine House Wall I/O Control Cabinet I/O and Controller Operator Cab I/O Operator Cab Touch Screen Auxiliary I/O Control Room Touch Screen

40 Front Machine House I/O Drop Added for more localized control and cabling Old system split this control between the lube room and right hand room Room for expansion

41 Lower Works I/O (located on the lower works) Transfer Cabinet I/O Hoist I/O Lube Room I/O Converter I/O RPC I/O Front Machine House Wall I/O Control Cabinet I/O and Controller Operator Cab I/O Operator Cab Touch Screen Auxiliary I/O Control Room Touch Screen

42 Lower Control Cabinet Flex I/O Siemens Smart I/O All new components

43 New 24vdc Components Typical Brake Box Transducers & new 24vdc brake solenoids Solenoid (MAC) Valves 24vdc coils

44 Results Demonstrated an improvement of 0.52 seconds in the dig cycle Demonstrated an improvement of 6.73 seconds improvement in the time it takes to switch from dig to propel and back System-wide availability was 93% for all hours of operation during the trial period and has been 93-94% post commissioning All systems passed MSHA regulations for safe and efficient operation All electrical and control systems fully integrated and met all electrical codes All components and equipment were designed and installed for reasonable ease of access and maintenance

45 Questions?

46 Vision Statement Our vision is to be the surface mining industry s preferred partner -- continuously striving to provide reliable, innovative products and services that reduce our customers costs

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