Attachment B
Edward John Reynolds
also known as Ted Reynolds
Electrical Engineer
Education
Bachelor of Engineering (Electrical) University of Newcastle, NSW
Professional Affiliations
Fellow, Institution of Engineers, Australia
Member, Institute of Electrical and Electronics Engineers Inc
Summary of Experience
Wide experience in supervising electrical aspects of complex industrial plants including power
distribution systems, electric drives, control systems. Experience encompasses all stages of
projects including pre-feasibility studies, conceptual designs, detailed design, equipment
specifications, construction and commissioning.
Experience in conducting investigations into a range of high voltage electrical equipment
failures.
Relevant Experience
E J Reynolds Consulting Pty Ltd. Managing Director and Principal Engineer of consulting
business which specialises in the area of electrical power distribution for industrial sites. Recent
assignments have included:
 Ongoing support of the Power System Reliability Improvement Project for Newcrest
Mining Telfer Gold Mine;
 Subject Matter Expert review of Safety Assurance Reports for Traction Power and High
Voltage Power Distribution for the Epping to Chatswood Rail Link;
 Substation Project Engineer for KBR on Rio Tinto’s Hope Downs Stage 1 Project WA;
 Investigation of power outages at BHP Billiton’s Olympic Dam 132/11 kV substation at
Olympic Dam SA;
 Investigation of reliability improvement program for Newcrest Mining Telfer Gold Mine
WA;
 System design studies and 220/33 kV substation design reviews for Austrian Energy for
the Cape Preston Mine Power Station. Cape Preston WA;
Page 1 of 7













Feasibility study for the upgrade of 3.3 kV power distribution in the Hot Flat Products
area of BlueScope Steel's Port Kembla works;
Feasibility study of the upgrade of the 33 kV distribution system at OneSteel's Whyalla
steelworks;
Review of loading, fault levels, protection and harmonic voltage distortion at the Yennora
works of ALCOA;
Investigation of power factor correction and harmonic filtering requirements for the
replacement of synchronous motor MG sets at BlueScope Steel's Springhill works;
Due diligence inspection of the Flanders Electric factory and design facilities Evansville
Indiana USA for BHP Billiton Mitsubishi Alliance Coal (BMA) as part of the award of a
contract to Flanders to remanufacture rotating electrical machinery for a secondhand
dragline purchased by BMA;
Investigation of fire in a 6.6 kV to 415 V substation at BlueScope Steel Western Port
works in Victoria;
Investigation of coupling of 22 kV earth fault current into low voltage circuits at 110/22
kV substation at the Bell Bay, Tasmania, works of TEMCO;
Investigation of failure of 3.3 kV fused vacuum contactor motor starter for New Zealand
Steel Glenbrook Hot Strip Mill;
Fault and load flow studies for co-generation plant for BlueScope Steel Port Kembla
Steelworks;
Prepare Expert Witness Report for Nation Wide Expert Witness Services for a matter
before the NSW Supreme Court;
Investigation of 6.6 kV bulk oil circuit breaker failure at BlueScope Steel Springhill
works.
Fault studies and overcurrent protection coordination for industrial site 22 kV /415 V
substation Burnie Tasmania;
Investigation of overcurrent tripping of electric arc ladle furnace for OneSteel Whyalla
South Australia
Hatch Associates, Australia, Automation and Power Systems Product Group. Principal
Electrical Engineer. Team Leader for Automation and Power Systems Product Group Sydney
and Newcastle team. Responsible for the development of Power Systems and Electro-technology
capability into a stand alone business in Australia. Responsible for supervising a team of
specialist engineer working in the areas of high voltage and low voltage power distribution
systems. Undertake specialist assignments on an as required basis. Specialist assignments during
this period included:
 Investigation of the effects on the 66 kV power distribution system resulting from the
energisation of a 25 MVA, 66/22 kV transportable substation at BHP Coal’s Peak Downs
Coal Mine, Qld;
Page 2 of 7




Investigation of tripping of variable speed drives resulting from power system transients
at Port Kembla Copper, NSW;
Review and risk assessment of 11 kV main distribution switchboard for CSR Sugar
Victoria Mill Ingham, Qld;
Screening study of high voltage power distribution system for a copper mine and
processing plant operated by BHP Tintaya SA Peru;
Site visit to BHP Tintaya SA Peru to assist with investigation of operational problems
with the plant high voltage distribution system.
BHP Engineering, Australia, Electrical Power Systems Product Group. Principal Electrical
Engineer. Team Leader for Electrical Power Systems Product Group Sydney team. Reporting to
Electrical Power Systems Product Group Manager. Responsible for supervising a group of
specialist engineers working in the area of both high voltage and low voltage power distribution
systems. Specialist assignments during this period have included:
 Review of high voltage power distribution system reliability following closure of steel
making at BHP Newcastle works in 1999;
 Review of high voltage cable terminations and over current protection system at BHP
Port Kembla works;
 Review of 600 V DC traction system power supply and distribution for automatic rail
haulage system for WMC at Olympic Dam.
BHP Engineering, Australia, Sydney Operations Electrical Department. Senior Supervising
Electrical Engineer. Responsible for managing Sydney Operations Electrical Department and
undertaking specialist assignments. Specialist assignment included:
Participate in the formation of BHP Steel Electrical Safety Committee including contributions to
electrical safety workshops;
 Participate in the team assembled to investigate the plant wide blackout at BHP
Integrated Steel Port Kembla works on 24 November 1997. Principal task was to
establish the root causes of the failure of the high voltage equipment which caused the
blackout;
 Investigation of harmonic filter equipment failure and harmonic interference on 13.8 kV
distribution system at BHP’s Pacific North West Plant, Kalama River, Washington USA;
 Review of electrical systems design for copper oxide ore leaching, solvent extraction and
electro-winning plant Escondida Chile;
 Strategic review of the development of the 33 kV distribution system for BHP Whyalla
steelworks;
 Investigation of 350 kVA, 6.6kV dry type transformer failures at BHP Spring Hill works;
 A visit to Mexico to witness factory testing of 140 MVA, 345kV/34.5kV transformers
which had previously failed under test.
Page 3 of 7
BHP Engineering, Australia, Sydney Operations Electrical Department. Senior Supervising
Electrical Engineer. Responsible for supervision of specialist power systems group at North
Sydney office. Projects included:
 The design, procurement, installation and commissioning of 33 kV, 6.6 kV and 415 V
power distribution systems for a steel technology development plant. Systems included
extensive modification to an existing 45 MVAr, 33 kV harmonic filter to accommodate
an increase in harmonic current generation from an electric arc furnace and new variable
speed rolling mill main drive;
 Investigation into the failure of a 22 kV to 900 V, 60 / 72 MVA electric arc furnace
transformer;
 Investigation into the failure of 11 kV to 415 V compact substation in Malaysia.
BHP Engineering, Australia. Sydney Steel Mill Project Stage 2 Development. Senior
Supervising Electrical Engineer. Responsible for supervision of electrical design for Stage 2
development of the Sydney Steel Mill project which added a bar rolling mill to the melt shop and
billet caster from the Stage 1 Development.
BHP Engineering, Australia. Sydney Steel Mill Project Stage 1 Development. Senior
Supervising Electrical Engineer. Responsible for supervision of a team of electrical engineers
and technical officers carrying out electrical design and commissioning of Stage 1 of the Sydney
Steel Mill. This stage of the project comprised an electric arc furnace melt shop and continuous
billet caster.
BHP Engineering, Australia. Senior Supervising Electrical Engineer. Responsible for
supervision of specialist power system group. Projects undertaken during this period include: Tasmanian Electro Metallurgical Co (TEMCO) - No 5 Ferro Alloy Electric Arc Furnace
Transformer failure. Investigation of failure and witnessing of repairs.
 Power and Services Risks and Operability Study for BHP Whyalla Steelworks.
 UPS and Standby generator system for Bankers Trust Australia data centre.
BHP Engineering, Australia. Supervising Electrical Engineer. Overall supervision of electrical
design, procurement, installation and commissioning of major and minor projects. Projects and
areas of responsibility included:
 Electrolytic Manganese Dioxide (EMD) Project at Newcastle;
 Manganese Metal plant feasibility study;
 Dust suppression spray system for BHP's Port Kembla Steelworks, design, procurement
installation and commissioning of electrical equipment and controls.
Page 4 of 7
BHP Engineering, Australia Comsteel Meltshop Redevelopment Project. Design CoOrdinator. Overall design co-ordination for the Comsteel Electric Arc Furnace Meltshop
redevelopment Project (capacity upgrade to 160,000 tpa).
Responsible for this project from feasibility study and conceptual design to final commissioning.
A study tour of electric arc steelmaking and ladle metallurgy facilities in UK and Germany was
undertaken as part of the project.
BHP Engineering, Australia. Brisbane Steel Market Mill Project. Senior Electrical Engineer.
Responsible for overseeing the electrical design for 130,000 tpa Brisbane Steel Market Mill
project. Tasks for this project included feasibility study and preparation of capital cost estimates
for mill electrical equipment and supervision of the conceptual design and specification of mill
electrical equipment.
Also responsible for overseeing electrical design for upgrade of main drive system for Hot Strip
Mill project at BHP Steelworks, Port Kembla.
BHP Engineering, Australia. Kooragang Island Coal Loader Project. Senior Electrical
Engineer. Responsible for design, installation and commissioning of electrical equipment
forming part of a 15 mtpa coal loader facility, including 33 kV switchgear, 33kV/6.6kV
transformers, 6.6 kV distribution and motor control centres, 6.6 kV conveyor drives up to 800
kW, PLC and computer control systems and stacking, reclaiming and shiploading machine
electrical equipment.
A study tour of coal loading, unloading and coal handling facilities in Japan, Netherlands, Italy
and South Africa was undertaken during 1981 as part of this project.
BHP Newcastle Steelworks, Australia. Electrical Engineer. Eleven years experience in design
and commissioning of electrical equipment for major and minor capital projects at BHP’s
Newcastle Steelworks. Experience was gained in the following areas:
 Hot rolling mill main and auxiliary drives;
 Ore unloading cranes;
 Sinter plants and blast furnaces.
BHP Newcastle Steelworks, Australia. Student Cadet - Electrical. Two years part time and
three years full time study at the University of Newcastle, NSW. Practical experience was gained
in electrical maintenance in various departments at BHP’s Newcastle Steelworks.
Page 5 of 7
Career History
7/2001 - present
1999 - 7/2001
1998 - 1999
1995 - 1998
1993 – 1995
1992 - 1993
1991 - 1992
1987 - 1991
1985 - 1987
1984 - 1985
1981 - 1984
1969 - 1981
1965 - 1969
E J Reynolds Consulting Pty Ltd Managing Director and Principal Engineer
Principal Electrical Engineer. Hatch, Australia, Automation and Power
Systems Product Group.
BHPBHP
Engineering,
Engineering,
Australia,
Australia,
Electrical
Electrical
Power
Power
Systems
Systems
Product
Product
Group.
Group. Principal Electrica
Principal Electrical Engineer.
BHP Engineering, Australia, Sydney Operations Electrical Department.
Senior Supervising Electrical Engineer.
BHP Engineering, Australia, Sydney Operations Electrical Department.
Senior Supervising Electrical Engineer.
BHP Engineering, Australia. Sydney Steel Mill Project Stage 2 Development,
Australia. Senior Supervising Electrical Engineer.
BHP Engineering, Australia Sydney Steel Mill Project Stage 1 Development,
Australia. Senior Supervising Electrical Engineer.
BHP Engineering, Australia. Supervising Electrical Engineer.
BHP Engineering, Australia. Comsteel Meltshop Project. Design Coordinator.
BHP Engineering, Australia. Brisbane Steel Market Mill Project. Senior
Electrical Engineer
BHP Engineering, Australia. Kooragang Island Coal Loader Project.
Senior Electrical Engineer.
BHP Newcastle Steelworks, Australia. Electrical Engineer.
BHP Newcastle Steelworks, Australia. Student Cadet - Electrical.
Page 6 of 7
Technical Papers
Co-author of paper titled "Control of Flicker Caused by an Electric Arc Steelmaking Furnace",
Journal of Electrical and Electronics Engineering, Australia, Volume II, No 2 June 1991, IREE
of Australia, IE Australia College of Electrical Engineers.
Professional Development
ESAA 1991 Short Course on Quality of Electrical Supply November 1991;
ESAA 1993 Short Course on Power Plant Control
ESAA 1995 Residential School in Electric Power Engineering;
CIGRE Pacific Power International 1996 Large Rotating Electrical Machines International
Seminar September 1996;
ESAA 2001 Short Course on Insulation Condition Monitoring and Partial Discharge Techniques;
CIGRE Transformer Technology Conference May 2006;
Asia Pacific TechCon 2006 May 2006;
IDC Technologies 2008 Practical Power System Protection for Engineers and Technicians July
2008;
IDC Technologies 2009 Earthing of Utility and Industrial Distribution Systems April 2009
Asia Pacific TechCon 2009 May 2009
Languages
English
Updated: 05/09
Page 7 of 7