Worry Free High Voltage Couplers WMEA Conference, San Antonio November 19, 2009 Presented by Nick Turner of KonNx Inc.

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1 Worry Free High Voltage Couplers WMEA Conference, San Antonio November 19, 2009 Presented by Nick Turner of KonNx Inc.

2 KONNX KonNx Inc Office, Warehouse and North American Distribution Denver, Colorado AUSPROOF Headquarters, Factory, and Global Distribution in Gladstone, Queensland, Australia

3 KONNX Non-Ferrous Foundry Computer Network from Design to Manufacture CNC Equipped Machine Workshop

4 Basic raw materials received Final product totally manufactured and ready for use

5 The Development Of The KONNX Cable Coupler Systems

6 PERFORMANCE RECORD OF COUPLERS IN SERVICE

7 Goal: Engineer out all the ways a high voltage coupler can fail. What made them fail?

8 RESEARCHING COUPLERS GLOBELY Designs around the World

9 Initial Findings Low voltage High voltage Quick Fix Solutions i.e. Teflon Electrical Type Tests For Connector Lower Than Requirement For Cable (making coupler weak link)

10 THE ULTIMATE TEST SHORT

13 AIR AND PARTIAL DISCHARGE Air Trapped Inside Coupler Enclosure Phase To Phase Flashover Existing couplers tested with results exceeding 20,000 pico-coulombs (pc). Extruded mining cable specifications call for an average 5 pico-coulombs. AIR PARTIAL DISCHARGE

14 SOLUTIONS Remove Air with Silicon Rubber Insert Insulating Material Developed to Extinguish Tracking Insulating Material Silicon Insert

15 NO TRIPS OR ANY SIGNS OF FAULT

16 ANALYSIS Silicon Rubber Insulating Material Stepping Stone

17 PHASE SEGREGATION BY EARTH Mining Industry Standard EARTH PHASE PHASE PHASE EARTH EARTH EARTH

18 FIRST SOLUTION A Phase to Ground Fault was created with conductive paint Earth Star Placed Between Phases A Through Fault Test was then performed on this solution to see how it would perform in the field

19 REASON FOR FAILURE PHASE 1 EARTH PHASE 2 PHASE 3

20 FINDING A SUCCESSFUL SOLUTION Equipotential Lines Good Equipotential Lines Good. Earth Star Equipotential Lines Crushed Up Individually Screened Cable

21 COUPLERS HOMOGENEOUS WITH CABLE EARTH CROSS SECTION ALL TYPE TESTS PERFORMED WERE WITHIN CABLE SPECIFICATIONS

Continuous rating of 800A TYPE TESTS PERFORMED ON NEW DESIGN

22 Current Contacts are of an eight finger design. Heat treated locking ring to maintain contact pressure. Continuous rating of 800A TYPE TESTS PERFORMED ON NEW DESIGN Temperature Rise at 800A Through Fault Test: 20kA for 0.3 sec 20kA for 0.3 sec 20kA for 1.0 sec Passed Passed Passed Passed

23 Voltage Type Tests Passed Impulse Voltage 125kV 10 Pos. Shots and 10 Neg. Shots A/C High Voltage Withstand 50kV for 1 min 35kV for 6 hours Partial Discharge 10pC Prior to 6 hour high voltage withstand 0.6pC After 6 hour high voltage withstand

24 Comparison Coupler Now As Good As The Cable

25 From Partial Solution to the Complete Solution

incorporates adjustments to maintain tension on cable over time.

26 Water Ingression Existing round O-ring seal Square section silicon face seals with a life of 30 yrs Tested to IP 68 Standard IEC Cable Glands KonNx gland incorporates adjustments to maintain tension on cable over time. Design will tighten on cable if tension on cable is applied. Glands are design specifically for cable sizes.

27 Special Cold Pour Developed with 3M

28 Bi-Sexual Design All male couplers. Guide pins assist alignment. All Silicon 800amp female/female Phase connectors w/rockwell hardened lock rings MSHA Compliance.

29 Enclosed slide hammers. Earth pilot attachment. Coupling tool. Tools & Coupling After together use four bolts to secure

30 Integrated Handling System For Surface Mining Applications Assists with opening and closing couplers One man operation Able to relocate couplers while energized. Protection for the joint. Roll-over. Skid wear pads. Cable clamp at each end. No tools required

33 Research & Development 5% of annual income Latest Development is integrated Fiber Optics Benefits to the Mining Industry Eliminating risk of phase to phase faults. Reducing the risk of phase to ground faults Fully integrated handling systems. Couplers do not limit the power supply to machines (All couplers continuously rated at 800 amps) Eliminates need for male/female cable orientation We listen to our customers and keep improving our products Increase in expected life of coupler. Over 1000 of our couplers in service since 1992 with no problems

34 Track Record 25kV couplers operating in Australian mines since In excess of 2000 couplers in Australia, South Africa, South America, North America and Asia Specified 25kV coupler by BHP Billiton. Rio Tinto. Xstrata Coal. Anglo American Coal Arch Minerals Cline Resources Signal Peak Energy

35 Track Record Specified 15kv Couplers by: GCC Energy Prairie States Energy Project ICG Consol Energy Specified 8kV Couplers by: BHP San Juan Mine Arch Minerals Signal Peak Energy Patriot Coal FMC Chemicals

36 KonNx

22kV 425 AMP KA STYLE COUPLER 224BKA - Range

DESIGNERS, MANUFACTURERS AND SUPPLIERS OF HIGH VOLTAGE BOLTED COUPLER & ADAPTOR SYSTEMS 22kV 425 AMP KA STYLE COUPLER 224BKA - Range Document Number: TM_461 Ver: 3 ausproof.com.au The Ausproof high voltage