The basic physical Principles and Definition


of Explosion Protection

• An explosion is the sudden chemical reaction of a flammable

material with oxygen with the simultaneous release of high energy.
• Flammable materials may be present in the form of gases,
vapours, mists or dusts. In order for a fire or explosion to occur
three conditions must exist:
1. Flammable material (in ignitable quantities)
2. Oxygen (in the air)
3. Ignition source
• The flash point of a flammable liquid is the minimum temperature
at which a liquid gives off vapour in sufficient concentration to form
an ignitable mixture with air near the surface of the liquid (at
normal air pressure). If the flash point of a flammable liquid is far
above the maximum temperatures which arise, an explosive
atmosphere may not be formed. The flash point of a mixture of
various liquids may be lower than that of the individual
components.
• If the concentration is too low
(lean mixture) or too high
(rich mixture), no explosion
occurs, rather there is just a
slow combustion reaction or
none at all.
• It is only in the range
between the lower and upper
explosion limit that the
mixture reacts explosively
when ignited. The explosion
limits depend on the ambient
pressure and the proportion
of oxygen in the air.
Explosion Limits of selected Gases
and Vapours
 Source of Ignition

• In order for an explosive atmosphere to ignite, a certain amount of energy
is needed. The minimum ignition energy is the smallest possible amount
of energy which is converted during the discharge of a capacitor and is
just enough to ignite the most ignitable mixture. The minimum ignition

energy is around 10-5J for hydrogen and a few joules for certain dusts.
• Ignition can be caused by various sources:
• hot surfaces
• • electrical arcs and sparks
• • electrostatic discharge
• • atmospheric discharge (lightning)
• • mechanical friction or impact sparks
• • electromagnetic radiation
• • adiabatic compression (shock waves)
• • ionizing radiation
•
• optical radiation
• • chemical reactions
• • open flames
 Types of electrical protection used in
mines

• Flameproof protection :- In this type of protection the enclosure which
houses the electrical equipment is designed in a manner that the explosion
inside the enclosure due to ingress of explosive/flammable gas or vapour
will not be transmitted/communicated to outside hazardous atmosphere.
Main application: Switchgear and control, gear and indicating equipment, control
systems, motors, transformers, heating equipment, light fittings
• Intrinsically safe :- In this type of protection the equipment is designed in
such a manner that the electrical energy which can enter explosive
environment is so low or restricted in a manner that it cannot ignite a
explosive gas air mixture.
Main application: Measurement and control technology, communication
technology, sensors, actuators.
• Increased safety type of protection :- This type of protection is achieved by
adopting measures in the design and manufacture of electrical apparatus
to ensure security against occurrence of arcs, sparks and excessive
temperature.
Main application: Terminal and connection boxes, squirrel- cage motors, light
fittings
What is Flame Proof Enclosure?
• An enclosure for electrical machinery or apparatus
that will withstand, when the covers or other
access doors are properly secured, an internal
explosion of the flammable gas or vapour which
may enter or which may originate inside the
enclosure, without suffering damage and without
communicating the internal flammation (or
explosion) to the external flammable gas or
vapour in which it is designed to be used, through
any joints or other structural openings in the
enclosure.
 How explosives gases enter FLP
enclosure?
• The question is often asked as to how an equipment or enclosure
designed to prevent any flame from within to the outside could
possible have entry within the enclosure of the volatile or vapour
surrounding it?
• This entry is due to the fact that all apparatus are breathing types,
i.e. when the electrical enclosure is operating, it emits heat, which
invariably expands the air inside, expelling the same through
joints.
• When the electrical is switched off, the air inside contracts,
permitting the external atmosphere containing the volatile gas or
vapour to enter the enclosure.
• A sequence of these operations eventually reach a stage where the
concentration of the atmosphere within a enclosure becomes
ignitable explodes due to sparking or hot spot.
• When this occurs, the flames and hot gases within are prevented
from transmission to the outside due to the width of the joints and
the corresponding gaps provided.
Types of Flameproof Enclosures
The following types of flameproof enclosures are permissible:
• A totally-enclosed motor ( TE ) is a motor so constructed that the
enclosed air has no connection with the external air, but not
necessarily ‘ air-tight ‘.
• A totally-enclosed fan-cooled moter ( TEFC ) is a totally-enclosed
motor with augmented cooling by means of a fan driven by the
motor itself, blowing external air over the cooling surfaces and/or
through the cooling passages, if any, incorporated in the motor.
• A totally-enclosed separately air-cooled motor ( TESAC ) is a
totally enclosed motor with augmented cooling by means of a
separately-driven fan blowing external air over the cooling
surfaces and /or through the cooling passages, if any,
incorporated in the motor.
• A totally-enclosed water or other liquid-cooled motor ( TEWC ) is
a totally-enclosed motor with augmented cooling by means of
water or other liquid-cooled surfaces embodied in the motor itself.
 Design of FLP Enclosures
• “Flameproof enclosure” means an enclosure for electrical
machinery or apparatus that will withstand, when the covers
or other access doors are properly secured, an internal
explosion of the inflammable gas or vapour which may enter
or originate inside the enclosure, without suffering damage
and without communicating the internal flame (or explosion) to
the external inflammable gas or vapour in which it is designed
to be used, through any joints or other structural openings in
the closure.
• Some electrical apparatus can be hermetically sealed, but this
is impractical for most industrial electric power equipment.
• If an enclosure is able to breath, an external explosive
atmosphere will be able to enter the housing because of
temperature changes. Whenever an apparatus is switched off,
it will tend to suck in some off the outside atmosphere as it
cools.
• The principle of flameproof protection is to
place electrical equipment in an enclosure,
which does not need to be sealed, but
which will not ignite a surrounding gas if
the same explosive mixture is ignited
within enclosure.
• A flameproof enclosure is therefore in
effect a type of pressure vessel in which
all openings
 Design Features for Flame proof Joint/
Gap
• Coating with paint or powder-coat finish is not
permitted, Other coating material may be used if the
material and application procedure have been
shown not to adversely affect the flameproof
properties of the joint.
• A corrosion inhibiting grease may be applied to joint
surfaces before assembly. The grease, if applied,
shall be of a type that does not harden because of
ageing, does not contain an evaporating solvent,
and does not cause corrosion of the joint surfaces.
• Joint surfaces may be electroplated. The metal
plating, if applied, shall not be more than 0.008 mm
thick.
 Design Features for Flame proof Joint/
Gap
• Plastic deformation of enclosure is not permitted.
• Flame proof housing is of stout metal construction. Minimum
value of pressure that housing must withstand for methane
gas for enclosure volume of 2-100 cc and above 100 cc
should be 6 bars and 8 bars respectively.
• The flp enclosure should be a sheet steel having minimum
tensile strength of 34 kgf/ sq. cm. The light metal alloy or
aluminium body is not acceptable.
• Safety joints preventing the transmission of explosion may
be flanged, spigot or threaded.
• The flame path i.e. the shortest distance measured across
the face of the joints from the inner surface of the enclosure
to the outer surface is long enough and the joint is close
enough fit to prevent ignition of methane atmosphere outside
by the flames or hot gases produced by internal explosion.
 Design Features for Flame proof Joint/
Gap
• The joints of most mining equipment have minimum flame
paths of 25 mm with max. Clearance of 0.5 mm. A flame path
is never less than 12.5 mm.
• Holes for fixing bolts do not pass in to the enclosure, they are
either blind or they are in external flanges
• The heads of bolt, plugs and sockets should be shrouded.
They can be removed only with a box spanner or special key.
• Fixing bolts should be strong enough to resist internal
explosion pressure. Sizes of bolts and screws depend upon
size of enclosure and they must not be less than 6 mm.
• Glass windows in FLP apparatus are flat plates of toughened
or annealed glass not less than 6 mm thick.
• Connecting cable enters the terminal box indirectly through a
sealing chamber filled with solid setting bituminous compound.
•
 Design Features for Flame proof Joint/
Gap
• Plug and socket connections must be locked
mechanically or electrically so that they can not be
opened, if live.
• Electrical and mechanical elements inside the FLP
enclosure should be designed in such a way that
due to its normal overloading, temperature may
not rise in the outside of the enclosure beyond
200 degree celcius. Overheating of enclosure
beyond 600 degree may ignite methane mixture.
 ELECTRICAL CLEARANCES
• Flame front of a methane-air explosion produces
free ions that can cause a current to flow when the
front bridges two conductors of opposite polarity.
• If the voltage is high enough, this current can
increase to a value that would be self-sustaining,
and a dangerous arc discharge can occur.
• Arc discharges produced in this way could cause
premature failure of electrical equipment, produce
excessive heating, or burn through an enclosure
wall.
• Therefore safe levels of voltages and clearances are
required to protect XP enclosures from failures due
to arc discharges.
• The minimum arcing voltages
(single phase, ac) for various air
gaps are shown in Fig. 1 [2].
• Curve A shows the minimum arcing
voltage versus electrode spacing in
air.
• Curve B shows the minimum arcing
voltage versus electrode spacing in
a 9.8 percent methane-air mixture.
• For example, curve B indicates that
arcing will occur at a spacing of 1.2
inches if 5 000 V are impressed
across the electrodes in a 9.8
percent methane-air mixture
(compared to a spacing of 0.071 in
for normal atmosphere, as shown
in curve A). Therefore, a spacing of
1.8 in (0.106 in for curve A) should
provide adequate clearance for this
voltage.
• flameproof joint or flamepath: place where the
corresponding surfaces of two parts of an enclosure,
or the conjunction of enclosures, come together and
which prevents the transmission of an internal
explosion to the explosive gas atmosphere
surrounding the enclosure.
• width of flameproof joint, L: shortest path through
a flameproof joint from the inside to the outside of an
enclosure
• gap of flameproof joint, i :distance between the
corresponding surfaces of a flameproof joint when
the electrical apparatus enclosure has been
assembled
Non threaded Joints

• The width of joints shall

not be less than the
minimum values given in
Tables 1 and 2.
• The gap, if one exists,
between the surfaces of a
joint shall nowhere exceed
the maximum values given
in Tables 1 and 2.
• For flanged joints, there
shall be no intentional gap
between the surfaces,
except for quick acting
doors or covers.
Spigot Joints:

For the determination of the width L of spigot joints, one of the following
shall be taken into account,– the cylindrical part and the plane part (see
Figure 2a). 

In this case, the gap shall nowhere exceed the maximum values given in
Tables 1 and 2;

– the cylindrical part only (see Figure 2b). In this case, the plane part need
not comply with the requirements of Tables 1 and 2,
 Holes in joint surfaces
• Where a plane joint or the plane
part or partial cylindrical surface
of a joint is interrupted by holes
intended for the passage of
threaded fasteners for
assembling the parts of a
flameproof enclosure, the
distance / to the edge of the hole
shall be equal to or greater than
• - 6 mm when the width of joint L
is less than 12.5 mm,
• – 8 mm when the width of joint L
is equal to or greater than 12.5
mm but less than 25 mm,
• – 9 mm when the width of joint L
is equal to or greater than 25
mm.
Cable entry in to FLP Enclosure
• left: Cable system
with indirect entry
• centre: Cable system
with direct entry
• right: Conduit system
• Cable system with indirect entry: In the case of indirect
entry, the cables and lines are conducted via cable
entrances into a wiring space in the type of protection
”Increased safety” and connected to the terminals also
provided in ”Increased Safety”. From here, the individual
wires are conducted via flameproof line ducts into the
flame proof enclosure.
• Cable system with direct entry: In the case of direct
entry, the connecting lines are conducted directly into the
flameproof enclosure. Only cable glands which have
been specially certified for this purpose may be used for
this type of entry. The flexible gasket and the cable
sheath must form a gap through which no flames can
penetrate.
• Conduit system: In the case of installation using the
conduit system, the electrical lines are drawn as single
wires into enclosed metal tubes. The tubes are
connected to the housings by means of unions and
equipped with a seal at each entrance point.
• The entire conduit system is flame proof. The aim of the
seal is to prevent explosions which may occur inside the
housing from penetrating the pipeline. Otherwise
extremely high explosive pressures would be created as
a result of pre-compression in long cylindrical tubes. For
this reason, it is recommended that seals be installed not
just at the entrance points but at specific intervals. Drains
must be installed at low points at which condensate can
accumulate.
 Design of Intrinsically Safe Circuit
Apparatus
• IS is based on the principle of limiting the thermal and
electrical energy levels in the hazardous area to levels
that cannot cause an ignition of a specific hazardous
mixture in its most ignitable concentration.
• IS pertains to the minimum ignition temperature and the
minimum ignition electric energy required to cause a
specific group to ignite.
• The energy level provided by an IS circuit is low (»1 W)
and is used only to power up instruments with a low
energy demand.
 Design of Intrinsically Safe Circuit
Apparatus
• An intrinsically safe circuit may be powered from either a d.c.
Or an a.c. Source. The open circuit voltage never exceeds
25 V. The d.c. Circuits are supplied by certified primary
batteries usually by certified primary batteries usually 22.5 V
and for a.c. It is limited to 15 V r.m.s.( peak less than 25 V).
• The source of power supply must have a internal resistance
to restrict current exceeding 2.6 amps for a d.c. and 1.6
amps. for a.c anywhere in the circuit even under short circuit
condition.
• A 22.5 V battery must have an internal resistance of about
10 ohms. All certified transformers have a built in non
inductive resistance in series with the secondary winding of
the transformer so that the total impedance becomes 10
ohms. This transformer is enclosed in a FLP housing
because primary is connected to power supply.
 Design of Intrinsically Safe Circuit
Apparatus
• Testing of the circuit is done in a glass bell jar filled with
8.3 % methane air mixture where contact arrangement is
made by rotating moving electrodes to generate high
speed break flash. The test is considered satisfactory if:
• (a) there is no more than 20 ignitions with about 20000
sparks.
• (b) there is no ignition of the test mixture by the sparking
device after 1000 revolutions.
• To make an apparatus intinsically safe, there must be
means of absorbing the reactive energy that is released
when the circuit is broken and power obtainable from the
source of supply must be limited.
 Design of Intrinsically Safe Circuit
Apparatus
• All intrinsically safe circuits have three components: the
field device, referred to as the intrinsically safe
apparatus; the energy-limiting device, also known as a
barrier or intrinsically safe associated apparatus; and the
field wiring.
• An intrinsically safe apparatus (field device) is classified
either as a simple or non-simple device.
• A simple field device is one which will neither generate
nor store more than 1.2 volts, 0.1 amps, 25 mW or 20
μJ. Examples are simple contacts, thermocouples,
RTDs, LEDs, noninductive potentiometers, and resistors.
• A nonsimple device can create or store levels of energy
that exceed those listed above. Typical examples are
transmitters, transducers, solenoid valves, and relays.
 Design of Intrinsically Safe Circuit
Apparatus
• When these devices are approved as intrinsically
safe, under the entity concept, they have the
following entity parameters: Vmax (maximum voltage
allowed); Imax (maximum current allowed); Ci
(internal capacitance); and Li (internal inductance).
• Under a fault condition, excess voltage or current
could be transferred to the intrinsically safe
apparatus (field device). If the voltage or current
exceeds the apparatus’ Vmax or Imax, the device
can heat up or spark and ignite the gases in the
hazardous area. The Ci and Li values describe the
device‘s ability to store energy in the form of internal
capacitance and internal inductance.
• To protect the intrinsically safe apparatus in a
hazardous area, an energy-limiting device must be
installed. This is commonly referred to as an
intrinsically safe associated apparatus or barrier.
Under normal conditions, the device is passive and
allows the intrinsically safe apparatus to function
properly.
• Under fault conditions, it protects the field circuit by
preventing excess voltage and current from reaching
the hazardous area. The basic circuit diagram for an
intrinsically safe barrier is shown in Figure.
Barrier
 Design of Intrinsically Safe Circuit
Apparatus
• There are three components to a barrier that limit current
and voltage: a resistor, at least two zener diodes, and a
fuse.
• The resistor limits the current to a specific value known
as the short circuit current, Isc.
• The zener diode limits the voltage to a value referred to
as open circuit voltage, Voc. The fuse will blow when the
diode conducts. This interrupts the circuit, which
prevents the diode from burning and allowing excess
voltage to reach the hazardous area.
• There are at least two zener diodes in parallel in each
intrinsically safe barrier. If one diode should fail, the other
will operate providing complete protection.
• A simple analogy is a restriction in a water pipe
with an overpressure shut-off valve. The restriction
prevents too much water from flowing through the
point, just like the resistor in the barrier limits
current. If too much pressure builds up behind the
restriction, the overpressure shutoff valve turns off
all the flow in the pipe.
• This is similar to what the zener diode and fuse do
with excess voltage. If the input voltage exceeds
the allowable limit, the diode shorts the input
voltage to ground and the fuse blows, shutting off
electrical power to the hazardous area.
Current use of intrinsically safe

apparatus in hazardous areas.
• These simple devices do not need to be
approved as intrinsically safe. If they are
connected to an approved intrinsically safe
associated apparatus (barrier), the circuit
is considered intrinsically safe.
Current use of intrinsically safe apparatus
in hazardous areas.
Ignition Current Vs Voltage for Hazardous
atmosphere
 Electrical Switches used in mines for
power transmission
• “Circuit breaker” means a device, capable of making and
breaking the circuit under all conditions, and unless
otherwise specified, so designed as to break the current
automatically under abnormal conditions like overloads,
earth fault.
• “Switchgear” shall denote switches, circuit breakers, cut-outs
and other apparatus used for the operation, regulation and
control of circuits. It is a general term covering switching and
interrupting devices and assemblies of those devicesbwith
control metering and protective equipment.
• Isolators in circuit breakerbare usedvto disconnect a circuit
from live bus bars when work has to be carried out on the
circuit. Isolators are not normally designed to make or break
a circuit while current is flowing.
• Switchgear is used to
isolate and protect high
voltage circuits in
underground mines,
surface mines, and
surface substations.
 Electrical Switches used in mines for
power transmission
• The essential parts of any circuit breakers are its
contacts. Arc control is an essential factor in the
design of switch gears. Switchgears are classified by
the arc suppression arrangement.
• 1. Air circuit breaker- used in medium and low
voltage system
• 2. Oil circuit breaker- used in high voltage system.
The contacts are emerged in oil. Not used in
underground mines.
• 3. Gas circuit breaker- sulpher hexa floride is used
for arc suppression.
• Vaccum circuit breaker
 Gate End Box
• A gate end box is a flame proof enclosure housing an electrical
control circuit, pilt circuit and a contactor. Its duty is to make and
break a motor circuit.
• The unit has facilities for connection of a trailing cable to the
machine.
• The upper FLP compartment of a gate end box accommodates bus
bars and isolators ammeters.
• The lower compartment accommodates contactor, protection
devices, intrinsically safe control circuit, auxilarry supplies to control
auxilary equipment, auxilary cable ways, main incoming and
outgoing cable.
• The following features are mounted on main front cover: push button,
earth leakage test, earth leakage indicator lamp, short circuit lamp,
pilot/earth short circuit test switch, inpu sequence selection swtch.
Protection devices in Gate End Box
• Earth leakage protection: it is set to trip if the fault current
exceeds a preset value.
• Pilot core protection: an intrinsically safe lockout circuit
prevents the closure of the main contactor in case of fault
being present in the main outgoing supply.
• Interlocking between mechanical and electrical system:
panel door can only be opened when the isolator is in off
position.
• Under voltage or no voltage protection: it trips the circuit if
the supply fails.
• Overcurrent and short circuit protection: with adjustable
overload setting devices and rapid acting short circuit
protection.
Protection devices in Gate End Box
• Pilot circuit: coal face machines like SDL,
LHD, DRILL MACHINES are switched on
and off by means of a remote contol circuit
known as pilot circuit. A pilot circuit is
intrinsically safe. The supply for the pilot
circuit is taken from a transformer in the
gate end panel and the pilot circuit is
completed through the trailing cable which
supplies power to the machine.
• Advantages of Pilot circuit

• High voltage arcing during switching on or off the

machine at the main contacts from the coal face site
is shifted to the gate end box.

• Machine controller function is transferred to the gate
end circuit breaker which reduces the size of the
machine.

• Trailing cable becomes dead when the machine is
not working.

• Machine can not self start when the power supply is
restored after failure.

• Machine will not start if earth continuity is interrupted.
Gate End Box
• A flameproof enclosure primarily for use at or near the
coalface and designed to line up with similar boxes to
form a control board.

• A gate-end box may contain bus bars, isolators,
switches, contactors, transformers, and protective
devices, for the control of motors, lighting, and other
equipment.



• Mechanically and electrically interlocked Isolator
mounted in a separate flameproof chamber.

• Visual indication of disengagement of Isolator/and
Earth connection contacts possible through special
window for additional safety.

• Earth leakage protections

• Visual indication of earth trip with test and reset
buttons provided on front cover.

• overload protection, short circuit protection, single
phasing protection

• Incoming and outgoing cable entries are provided
through cable terminal boxes, cable couplers and
adopters.

• Through going cable entries are possible through
throughgoing cable entry boxes

• ammeters, voltmeter, insulation monitoring meter etc.
are available

 Drill Panels (Flameproof Single Unit
Drill)
• These are available for
operation at 550 volts
primary and 110 volts
secondary.

• earth leakage protection

• Choice of thermal/solid state/
magnetic overload relays.

• airbreak contactors upto 50
amps

• Electrically and mechanically
interlocked Isolator mounted
in a separate enclosure.

• Outgoing cables through plug
and socket entry..

 Drill Panels (Flameproof Double Unit
Drill Panels)
• two drills can be simultaneously
operated from a single drill panel
with the help of a heavier
transformer.

• provision for mounting two sets of
plugs and sockets on the same
flameproof enclosure.

• single isolator both electrically and
mechanically interlocked with the
cover of the main enclosure.

• two separate sets of controls, and
motor-protective devices as
mentioned above.

• extremely versatile and economical
equipment that saves cabling cost
for running two separate drill panels
at the same face.

 Mining Cables
• All cables used in mines are manufactured
according to IS followed by approval s
from DGMS.
IS 1827-68 Wire armoured lead cover paper
insulated cable
IS 1554 PVC insulated electric cable
IS 1027 Paper insulated cable
IS6346 Armoured PVC insulated cable
IS 691 Rubber insulated flexible trailing
cable for coal mines
IS 1026 Flexible trailing cable
Is 5950 Shot firing cables
IS 708 Trailing cables
 Mining Cables
• Trailing Cables: Here the insulation
material is of such a quality that allows
insulation and sheath thickness such
designed for slow reeling and trailing
applications with optimum flexibility, drum
capacity and mass.

• Armoured Cables:These are more robust
cables with a greater thickness of
insulation and sheath.
 Mining Cables
• Cable design considers the following aspect:

• Conductor insulation

• Conductor size and layout

• Conductivity

• Insulation protection

• Flexibility

• Resistance to abuses and hostile environment

• Cable faults and monitoring
Cable construction parts
• Conductor :Usually stranded copper (Cu) or
aluminium (Al). Copper is densier and heavier,
but more conductive than aluminium.
Electrically equivalent aluminium conductors
have a cross-sectional area approximately 1.6
times larger than copper, but are half the weight
(which may save on material cost).

• Conductor Screen :A semi-conducting tape to
maintain a uniform electric field and minimise
electrostatic stresses (for MV/HV power cables).

• Insulation :Commonly thermoplastic (eg. PVC) or thermosetting (eg.
Ethylene -propylene based synthetic rubber (EPR), cross linked
polythelene ( XLPE), synthetic butyl rubber, neoprenne based synthetic
rubber ) type materials. Typically a thermosetting(eg. EPR, XLPE) or
paper/lead insulation for cables under 22kV. The cable current load range
is controlled by the type of conductor insulation, because loading capacity
is limited by heating which in turn depends upon current density.

• Plastics are one of the more commonly used types of insulating
materials for electrical conductors. It has good insulating, flexibility, and
moisture-resistant qualities. Although there are many types of plastic
insulating materials, thermoplastic is one of the most common. With the
use of thermoplastic, the conductor temperature can be higher than with
some other types of insulating materials without damage to the insulating
quality of the material. Plastic insulation is normally used for low- or
medium-range voltage.

• Insulation Screen:A semi-conducting material that has a similar function
as the conductor screen (ie. control of the electric field for MV/HV power
cables).

• Conductor Sheath :A conductive sheath / shield, typically of copper
tape or sometimes lead alloy, is used as a shield to keep
electromagnetic radiation in, and also provide a path for fault and
leakage currents (sheaths are earthed at one cable end). Lead
sheaths are heavier and potentially more difficult to terminate than
copper tape, but generally provide better earth fault capacity.

• Filler :The interstices of the insulated conductor bundle is sometimes
filled, usually with a soft polymer material.

• Bedding / Inner Sheath :Typically a thermoplastic (eg. PVC) or
thermosetting compound, the inner sheath is there to keep the bundle
together and to provide a bedding for the cable armour.

• Individual Screen (Instrument Cables)

• An individual screen is occasionally applied over each insulated
conductor bundle for shielding against noise / radiation and
interference from other conductor bundles. Screens are usually a
metallic (copper, aluminium) or semi-metallic (PETP/Al) tape or braid.
Typically used in instrument cables, but not in power cables.

• Armour :For mechanical protection of the conductor bundle. Steel wire
armour or braid is typically used. Tinning or galvanising is used for rust
prevention. Phosphor bronze or tinned copper braid is also used when steel
armour is not allowed.

• SWA - Steel wire armour, used in multi-core cables (magnetic),

• AWA - Aluminium wire armour, used in single-core cables (non-magnetic).

• When an electric current passes through a cable it produces a magnetic field
(the higher the voltage the bigger the field). The magnetic field will induce an
electric current in steel armour (eddy currents), which can cause overheating
in AC systems. The non-magnetic aluminium armour prevents this from
happening.

• Outer Sheath :Applied over the armour for overall mechanical, weather,
chemical and electrical protection. Typically a thermoplastic (eg. PVC) or
thermosetting(eg. CSP) compound, and often the same material as the
bedding. Outer sheath is normally colour coded to differentiate between LV,
HV and instrumentation cables. Manufacturer’s markings and length
markings are also printed on the outer sheath.



 Mining cables
• Electrical distribution systems and cables have to be designed so that in
the event of damage to a cable, the risk of electrocuting someone, causing
a major fire, catastrophic failure of the cable or igniting methane gas has to
be minimised.

• When selecting cables, apart from considering the type of application and
the harsh mining environment (mining cables are particularly susceptible to
damage), the electrical distribution system is an important factor.

• The electrical distribution system protection and method of earthing is
particularly important. If the incorrect cable is selected, the safeguards
provided by the electrical protection and the earthing may be compromised.

• All underground coal mine electrical distribution systems are designed to
limit the

• amount of current that can flow in the event of an earth fault, typical values
are 5, 10 and 25 amperes, most commonly 5 amperes at the working face.
This means that when a cable is damaged and the fault is from a conductor
to earth, the amount of energy released is reduced significantly from that of
a solidly earthed electrical distribution system.
• A key feature of most of the mining cables is the provision of
earthed screens around each individual power conductor. These
screens are provided so that if a cable gets damaged the most
likely type of fault is an earth fault.

• Other key features of the design of cables are:

• Electrical symmetry for cables that can carry high current. This is
provided to prevent currents being induced in earth conductors and
thus raising the earth potential of individual machines above the
normal 0 volts. If this induction is not controlled, then it is possible
for one machine to be at a different earth potential to another, and if
they touch there will be a spark between the two machines. In a
coal mine this spark has the potential to ignite methane gas and
cause an explosion with catastrophic consequences.
• Fire resistance of cable sheaths and
insulation. If a fire does commence then
once the ignition source is removed the
fires will self extinguish within a short time.
Main cables for shaft and incline
• Mass impregneted non draining paper insulated lead
covered double wire armoured cables are used in shaft and
inclines.

• To make the cable non draining or non bleeding type, the
cores are dried under vaccum (155 degree C ) and pressure
impregnated at 121 degree with compound of mineral oil
gelled by the addition of micro crystalline wax resin.

• The paper insulted core is covered by lead tube to exclude
moistureand the same is covered by compound impregnated
jute that acts as a bedding for single or double wire steel
armouring. The armouring acts as an earth conductor.

•
 pliable armoured cables
• It is used underground for power supplies
to fixed or semipermanent equipment such
as pumps, conveyors, stage loaders etc.

• It generally include screened rubber
insulated power cores laid round on poly-
chloroprene centre.

• Pliable armoured cables have four or five
cores, one being used as earth and other
as pilot core.
 Trailing cables
• It is used for supplying power to portable equipment such as.
Ccm, cutter loaders, drills SDL, LHD etc.

• It should be light in weight, mechanically strong, flexible with no
risk of shock or fire.

• The outer sheath must be able to resist impact, friction,
compression, temperature, oil and grease, humadity, radiation
and water absorption.

• Trailing cables have five cores, three for power, one earth and
one pilot core.

• Most of the modern trailing cables are of the individually
screened type where the screens are earhed. Individual screens
reduces the possibility of a short circuit between the live cores.
Individually screened Collectively screened
Screened pliable armoured cable
• Trailing and reeling cables are electrical power
cables for mobile apparatus, such as large
excavators, draglines, stackers and reclaimers.
The cable permits the mobile apparatus to
move without disconnecting its electric power
supply. A reeling cable is specifically designed
to be frequently reeled on and off a cable drum
or reeler (e.g. an iron ore rail-mounted
reclaimer), whereas a trailing cable is
specifically designed to be moved with the
mobile apparatus

Copper screened cable for
hand-held boring
machines and drills.
Contains a central pilot for
earth continuity
suitable for earth continuity
or for control.
Overall semiconductive rubber
screened cable for shuttle cars
and pump cable. Earth cores
designed to reduce instances
of wire breaks during reeling
while under tension. Cable
includes one central pilot
monitoring.
Semiconductive screened cable
for various uses, including main
feeder cable for continuous
miners, pump cable, and power
supply cable. Overall
semiconductive screen provides
protective earth contact for any
object breaching the
sheath prior to contact with power
conductors. Cable contains one
central pilot suitable for earth
continuity monitoring.
Semiconductive screened
and very flexible cable for
use as longwall shearer
cable. The very flexible
conductor allows for much
reduced bending radii so this
cable will tolerate bending in
the cable chain. Cable has 3
central pilots for earth
continuity monitoring and for
control circuits.
Copper screened cable for
power supply. May be used as
feeder to machinery or
longwall supply.
protection and strength is
Cable contains 3 large pilots
and large core screens provide
for low resistance earthing.
Copper screened and pliable
armoured cable for use as
supply cable where mechanical
required. May be used as a
feeder cable to machinery and
suitable for sandmining
operations
 Circuit Breakers
• A circuit breaker is a manually or automatically operated electrical
switch designed to protect an electrical circuit from damage caused
by overload or short circuit.

• Its basic function is to detect a fault condition and interrupt current
flow. Unlike a fuse, which operates once and then must be replaced,
a circuit breaker can be reset (either manually or automatically) to
resume normal operation.

• Once a fault is detected, contacts within the circuit breaker must
open to interrupt the circuit; some mechanically-stored energy (using
something such as springs or compressed air) contained within the
breaker is used to separate the contacts.

• The circuit breaker contacts must carry the load current without
excessive heating, and must also withstand the heat of the arc
produced when interrupting (opening) the circuit. Contacts are made
of copper or copper alloys, silver alloys and other highly conductive
materials.
 Circuit Breakers
• When a current is interrupted, an arc is generated. This arc must be contained,
cooled and extinguished in a controlled way, so that the gap between the
contacts can again withstand the voltage in the circuit. Different circuit breakers
use vacuum, air, insulating gas or oil as the medium the arc forms in.

• Low-voltage MCB uses air alone to extinguish the arc. Larger ratings have metal
plates or non-metallic arc chutes to divide and cool the arc. Magnetic blowout
coils or permanent magnets deflect the arc into the arc chute.

• In larger ratings, oil circuit breakers rely upon vaporization of some of the oil to
blast a jet of oil through the arc.

• Gas (usually sulfur hexafluoride) circuit breakers sometimes stretch the arc
using a magnetic field, and then rely upon the dielectric strength of the sulfur
hexafluoride (SF6) to quench the stretched arc.

• Vacuum circuit breakers have minimal arcing (as there is nothing to ionize other
than the contact material), so the arc quenches when it is stretched a very small
amount (<2–3 mm). Vacuum circuit breakers are frequently used in modern
medium-voltage switchgear to 38,000 volts.

• typically the arc is extinguished between 30 ms and 150 ms after the mechanism
has been tripped, depending upon age and construction of the device.
 Flameproof Air Break Air Circuit Breakers For
550 Volts (air & Vacuum Circuit Breakers)
• circuit breakers, which are
available for voltage upto 550
volts and current ratings upto,
400 amps.

• the main active chamber is fitted
with either an air break mccb, or,
a circuit breaker with self-
cleaning contacts

• the isolator is mounted in a
separate flameproof chamber
and is mechanically and
electrically interlocked with the
cover of the main enclosure.

• isolators are upto 400 amp
capacity
 Flameproof Foot Pedal Switches
(Mobile Machine Accessories)
• These are flameproof
push button stations
mounted with foot
pedals to operate as
pedal switches to
control the start/stop
functions on the
mobile machines