Mine Electrical Power

5.
Mine Electrical Power

INTRODUCTION
The application of electricity to the coal mining industry is unlike that of any other
industry. The combination of high power, mobile equipment, strict regulations, and a
wide range of operating environments, including explosive atmospheres, places unique
demands on the mine electrical system. Consequently, proper mine power system design
and operation requires knowledge of both mining and electrical engineering principles.
Effective mine management not only requires knowledge of production and safety
fundamentals but also familiarity with the electrical system.
Since that time, mining applications have continued to push the limits on electrical
systems and components. To this day, mining equipment comprises some of the largest
electrical machines operating under the most adverse conditions.
This objective of this chapter is to familiarize the reader with the basics of mine
power systems. First, an overview of power systems is provided, followed by a summary
of relevant federal regulations. Next, a review of AC circuit analysis, AC power, power
factor, and power factor correction is given. Balanced three-phase system analysis and
one-line diagrams are also covered. Major power system components, including cables,
substations, switchhouses, and power centers, are described. Finally, grounding systems
and grounding practices are discussed.
5. Mine Electrical Power
OVERVIEW OF MINE POWER SYSTEMS
Power System Fundamentals
In general, a power system consists of generation, transmission, distribution, and
utilization. Figure 5.1 shows the basic power system arrangement. Generation is
typically through large, threephase synchronous generators producing voltages from 11
to 22 kV. Transmission voltages may include, but not be limited to, 138, 230, 345, 500,
or 750 kV. Subtransmission voltages may range from 26 to 69 kV. Utilization voltage
can range from the common 120/240 V for households to several thousand volts for
industrial customers.
Figure 5.1 Basic power system arrangement

Coal mines in China ： 35kV— 矿井地面变电所变电电压； 10kV 或 6kV— 井下供配
电电压； 3kV 或 1140V— 综采工作面、高档普采工作面供电电压； 660V— 机采工
作面、机掘供电电压； 380V— 地面和小型矿车井下低压电网的配电电压； 220V—
地面和井底车场，总进风巷的照明电压； 127V— 手持式电动工具、照明、信号、
电话供电电压； 36V— 控制电气设备的限额电压；直流 250V 、 550V— 直流架线电
机车电源电压。
Figure 5.2 shows components of a simple mine power system. The mining company
receives electricity from the utility at the main substation. This may be at the utility
transmission, subtransmission, or distribution levels, depending on the location of the
mine and the configuration of the utility. Either the utility or the mining company can
own the substation, depending on the type of contract the company has with the utility.
The substation establishes the grounding system(s) and transforms utility voltage to the
mine distribution voltage while also protecting outgoing circuits. Major components of
the substation include the transformer, switches, protective devices, metering, grounding
components, and power factor correction capacitors. Common distribution voltages
typically range from 7.2 to 14.4 kV.
The power supply voltage

in mining areas is generally
35kV and 110kV (most of
Northeast China is 60kV),
and that in some large Figure 5.2 Simple mine
power system
mining areas is 220kV.
The switchhouse is a portable device that allows the distribution circuit to split or
branch. Major components include switches and protective devices such as relays and
circuit breakers to protect the branch circuits.
The power (or load) center can be considered to be a portable substation. It transforms
the distribution voltage to utilization levels and provides protection for each outgoing
circuit. Like the substation, typical components include the transformer, switches, and
protection equipment. Additional details on substations, switchhouses, and power
centers are given later in this chapter.
Figure 5.2 Simple mine power system

Distribution Arrangements
Several basic distribution arrangements are utilized for the mining industry, and
selection of a particular one is a function of need, cost, and mining method. For this
overview, only the most widely used arrangements will be discussed, including the
radial, expanded radial, primary selective, and primary loop systems.
(1) The radial system is the simplest and least expensive topology. There is one
substation and electricity is distributed throughout the mine at utilization levels.
Switchhouses are used to disconnect and distribute power to loads. A disadvantage of
the radial system is the lack of redundancy (i.e., a failure at the substation will result in
loss of service throughout the mine). Another disadvantage is high line loss and poor
voltage regulation because electricity is distributed throughout the mine at utilization
levels (IEEE 141-1993). The radial system is typically not used in the modern mining
industry but provides a conceptual foundation for other distribution systems that will be
discussed.
Distribution Arrangements
(2) The expanded radial system (Figure 5.3) also has a single source and substation, but
unlike the radial system, electricity is distributed at voltage levels that are higher than
utilization voltages. Power (or load) centers are used to reduce voltages from
distribution to utilization levels. Compared with the radial system, the expanded radial
system has the advantage of distributing electricity at higher voltage levels, thereby
reducing losses and permitting the use of smaller distribution cables. However, like the
radial system, the loss of the substation will result in loss of service throughout the mine
(IEEE 141-1993). The majority of surface and underground coal mines use the
expanded radial system.
Figure 5.3 Expanded

radial distribution system
OVERVIEW OF MINE POWER SYSTEMS Distribution Arrangements
(3) The primary selective system is similar to the expanded radial system with the
inclusion of an additional source and substation. Under normal operation, each source
supplies approximately onehalf of the mine. If one of the sources fails, the entire mine
(or at least most of it) can be supplied by the remaining source. The primary selective
system adds reliability to the system, but also cost, because of the need for two sources
and substations plus additional switchgear (IEEE 141-1993).
(4) The primary loop system (Figure 5.4) provides the reliability of a primary selective
system at lower cost. Because the distribution voltage is supplied in a loop
configuration, continuity of service is easily provided when one source fails (IEEE 141-
1993). However, this system could create safety hazards compared with other systems
because power is supplied to both sides of each component in the distribution system.
Figure 5.4 Primary loop distribution system

FEDERAL REGULATIONS
The application of electrical equipment in the mining industry is heavily regulated

by Title 30, Mineral Resources, of the Code of Federal Regulations. This level of
regulation is understandable when the conditions under which the equipment must
operate are considered. For example, electric mining machinery is generally cable
connected and many of the mining machines are mobile. This equipment must
operate safely in extreme conditions, including very cold or very hot ambient
temperatures, wet conditions, and in explosive atmospheres. These operating
conditions, coupled with a workforce that, in many cases, is unfamiliar with
electrical engineering fundamentals, makes it essential that the mine electrical
system and electrical equipment be designed to provide employee safety during both
normal and faulted conditions. Indeed, many of the designs and practices used in the
industry today are a direct result of regulations developed to make the use of
electricity in mining as safe as possible
CIRCUIT ANALYSIS REVIEW
By far, the majority of coal mine electrical loads are alternating current (AC). Some
direct current (DC) trolley systems and a significant number of battery-powered
vehicles are in use in today’s mines; however, many of them actually use AC drive
systems. For example, the Joy battery hauler uses an inverter to convert DC to AC
in conjunction with an AC variable frequency drive (AC-VFD) system (a DC drive
system is also available). The Phillips Freedom Car is a battery-powered shuttle car,
also with an AC-VFD system. Therefore, although there is some DC equipment in
coal mines, the emphasis in this chapter will be on AC power systems and modeling
AC loads. It is assumed that the reader is familiar with basic DC and AC circuit
analysis techniques; however, a brief review of some of the more commonly used
AC circuit analysis techniques and also AC power are provided in this section.
MINE CABLES
Mine power cables carry electricity from the substation to the electrical loads. As
such, cables are an integral part of the distribution and utilization systems.
Probably no other industry subjects cables to the wide range of conditions as does
the mining industry. In many cases, cables are connected directly to mobile
equipment and are subjected to harsh mining conditions such as extreme
temperatures, abrasion, flexure, tension, and so forth.
(1) Cable Types
There are several cable types, and the type selected depends on the application. For
example, some utilization cables that are connected to portable or mobile mining
equipment are moved very frequently and subjected to physical stress. Other cables
supply power to equipment such as shuttle cars or roof bolters that have cable reels
to automatically wind and unwind the cable. These cables must be flexible and able
to withstand the mechanical and thermal stresses associated with being wound onto
a reel. Distribution cables may be moved infrequently and not subjected to much
physical stress; however, these cables are subjected to higher voltage stress
compared with utilization cables. Finally, some cables are suspended vertically in a
borehole while others are exposed to extreme temperatures and/or ultraviolet (UV)
radiation. Three broad categories of cables are:
MINE CABLES
(1) Cable Types

• Borehole cable: Cable designed to be suspended vertically in a borehole or shaft.
• Mine power feeder: Cable designed for underground high-voltage distribution
where the cable is moved infrequently (less than once a year).
• Portable or trailing cable:
The Mine Safety and Health Administration (MSHA) defines a portable or trailing
cable as “a flame-resistant, flexible cable or cord through which electrical energy is
transmitted to a permissible machine or accessory. (A portable cable is that portion of the
power-supply system between the last short-circuit protective device, acceptable to
MSHA, in the system and the machine or accessory to which it transmits electrical
energy)” (30 CFR 18.2).
MINE CABLES
(2) Cable Components
Major cable components include conductors, insulation, shielding, and the jacket.
Other components may include fillers, binding, and armor. Only major components
are discussed in this section.
(3) Conductors
Conductors are the current-carrying component of a cable. Conductors include the
power conductors, grounding conductors, and, in some cables, a ground-check
conductor. Conductors may be copper or aluminum. Copper has higher conductivity
and is more flexible than aluminum, but it is also heavier and more expensive. Each
conductor is composed of numerous small wires bound together in strands to improve
conductor flexibility.
(4) Insulation
Insulation is used to separate conductors and keep current within its intended path.
Insulation surrounds each power conductor and also the groundcheck conductor, if
present in a cable. Grounding conductors are generally not insulated. Insulation must
withstand electrical, physical, and thermal stresses, and be relatively flexible for
certain applications.
MINE CABLES
(5) Shielding
In general, shielding helps to reduce voltage stress on the insulation and confine the
electric field to the insulation. Two types of shielding are used in cables. The first is
called the conductor (or strand) shield. The strand shield surrounds the conductor and
is firmly bonded to the insulation. Its purpose is to reduce or eliminate the voltage
stress in any voids that may be between the conductor and insulation.
The second type of shielding is the insulation shield. For situations where the
insulation shield is placed directly over the conductor insulation, it serves to confine
the electric field to the conductor insulation. The conductor shield also serves to
produce a symmetrical and radial voltage stress within the insulation, which reduces
the possibility of partial discharges.
Figure 5.22 shows the relationships

among the conductor, insulation,
strand shield, and insulation shield.
Figure 5.22 Strand and insulation shielding

MINE CABLES
(6) Jackets
The primary function of the cable jacket is to hold the inner components of the cable
in place and provide protection for them. The jacket must be resistant to abrasion,
crushing, tearing, moisture, chemicals, and sunlight. Neoprene, a chloroprene
polymer, is one material used for cable jackets. (Morley 2003). Chlorinated
polyethylene (CPE) is also used for cable jackets. CPE is relatively tough and
durable, and it can be made in different colors. Thermoplastic polyurethane (TPU) is
a popular jacket material for extremely abrasive environments. TPU is resistant to
UV rays and remains flexible in low temperatures (AmerCable 2011, 2012). Figure
5.23 shows a typical mine power feeder with the insulation removed to see the
various cable components.
Figure 5.23 Typical high-

voltage mine power feeder
MINE CABLES
(7) Conductor Sizing
Cable selection is as much an art as it is a science. Unlike the power systems of most
other industries, mine power systems are very dynamic. Distribution systems are in a
state of constant expansion (or contraction), and sections may be added or removed
as mining progresses. In addition, the mining process is very cyclic in nature, causing
load currents to fluctuate under normal operating conditions. The mining
environment can pose many challenges such as extreme temperatures, presence of oil
or chemicals, abrasion, mechanical stresses, and so forth. Consequently, complete
cable selection depends on many factors that are site specific and, therefore, beyond
the scope of this book. However, the general process for sizing power conductors can
be outlined.
Heating and voltage regulation are the two main issues to consider when sizing
conductors. Other factors, such as the ability to withstand short-circuit current and to
meet state and federal regulations, must also be considered for each specific
application. In this section, the procedure will consider heating and voltage drop only.
MINE CABLES
(8) Ampacity
Ampacity is the current-carrying ability of power conductors. Ampacity values are
based mainly on the ability of the cable assembly to dissipate heat caused by current.
The heat produced in the cable is primarily from the power (I2R) loss from the current
through the power conductor resistance. Five parameters are used to establish cable
ampacity (Morley 2003):
1. Conductor diameter and number of conductors in the cable,
2. Thickness of the conductor insulation and cable jacket,
3. Cable configuration and dimensions,
4. Heat-transfer properties of the cable components, and
5. Type of conductor and jacket, and the ambient temperature.
Ampacity values for typical three-conductor portable power cables are given in
Table 5.3. Table 5.4 lists ampacity values for three-conductor mine power feeders.
Each table considers a 40°C ambient temperature and a 90°C conductor temperature.
For ambient temperatures other than 40°C, the correction factors in Table 5.5 can be
applied. (Aluminum conductors are included in Table 5.4 but rarely used in mine
cables.)
Table 5.3 Ampacity values for portable power cables, amperes per conductor
AWG = American wire gauge. MCM = Thousand circular mils.

Table 5.4 Ampacity values for three-conductor mine power cables
Table 5.5 Ampacity correction factors for
various ambient temperatures
Equation 5.33 shows the calculation
for determining the average load
current:
Table 5.6 Typical power factor and

load factor values for selected
underground coal mining equipment
where
|I | = average RMS current, amperes(A)
P = average input power, watts(W)
LF = load factor, which is the ratio of the
average load to the rated (i.e., nameplate)
load
pf = power factor
|VLL|=the load RMS operating voltage, line
to line
In the absence of more precise information,
the values in Table 5.6 can be used.
SUBSTATIONS
A mine main substation is used to establish
the grounding system, transform utility
voltage to mine distribution voltage, and
protect outgoing circuits. The substation
includes numerous devices including
switches, protective relays, circuit breakers,
transformers, metering, power factor
correction capacitors, and so forth. Typical
utility supply voltages to the substation range
from 13.2 to 230 kV, depending on the
voltage levels available at or near the mine.
Output voltage levels from the substation to
the mine usually range from 7.2 to 14.4 kV.
Figure 5.27 shows a one-line diagram of
a typical mine substation. Table 5.10 lists the
ANSI/IEEE Standard device numbers for the
devices shown on
Figure 5.27. Each of these devices is Figure 5.27 One-line diagram of substation
discussed in subsequent subsections.
SUBSTATIONS (1) Transformer
The substation transformer is used to reduce the utility voltage to the mine
distribution voltage level. Typically, the substation transformer is immersed in oil that
serves as an insulator and coolant. Air cooled or dry-type transformers are rare, if used
at all for substation transformers. Transformers are usually mounted on concrete pads
within the substation.
Because of the cyclic nature of mining, precise determination of the transformer
size can be difficult. Notwithstanding, a good rule of thumb is for the transformer
capacity to be approximately 1 kVA for each horsepower of load connected to it. For
example, a 10,000-kVA substation transformer would be used for a mine that has a
total connected load of 9,300 hp.
SUBSTATIONS (2) Relays
Relays are used to detect voltage, current, or other power system anomalies and send
a trip signal to a circuit breaker. Relays may be electromechanical (e.g., an induction
disk relay) or they may be electronic. The term pickup is used to indicate the point at
which a relay changes from its normal state to a state that indicates a problem such
as an overload or short circuit. When a measured signal reaches the relay pickup
value, the relay sends a trip signal to a circuit breaker. The most common relays used
in mine power systems are voltage and current relays, although many other types
exist.
Overcurrent relays generally have instantaneous and/or inverse-time elements. As
the name implies, the instantaneous element sends a trip signal to the circuit breaker
with no intentional time delay when the pickup setting is exceeded. Instantaneous
settings are typically used to detect and de-energize faulted circuits. The inverse-
time relay element has an operating time that is approximately inversely proportional
to the current. This relay function is primarily used to protect the system from
overloads. The inverse-time characteristic permits small overloads for a relatively
long time, while large overloads will cause tripping in a much shorter time.
Inversetime relays can also be used to provide backup protection for downstream
relays that fail to operate during a fault.
SUBSTATIONS (2) Relays
Voltage relays pick up on either overvoltage or undervoltage conditions. Undervoltage
relays are frequently used to protect motors from running or starting when the voltage is
unacceptably low. Overvoltage relays are typically used to protect loads or circuits from
sustained overvoltage conditions and for ground-fault detection. As applied in
substations, overvoltage relays are used (with transformers) to detect ground faults by
measuring the voltage across the neutral grounding resistor that occurs when ground-fault
current flows through it. (Additional details are given later in the “Grounding” section of
this chapter.)
The device numbers listed in Table 5.10 are some of the most common relay
functions used in mine substations.
Table 5.10 Selected

ANSI/IEEE device numbers
SUBSTATIONS (3) Circuit Breakers
Circuit breakers (device 52) are used to
automatically open a circuit in the event of an
overload or short circuit. (Circuit breakers can
also be used to manually open the circuit.) High-
voltage circuit breakers typically receive the trip
signal from a relay, whereas low-voltage circuit
breakers will typically contain the trip units.
Substation circuit breakers are usually vacuum
circuit breakers (VCBs). As the name implies, the
contacts of a vacuum breaker are in a vacuum.
Because of the high dielectric strength of a Figure 5.28 15.5-kV, 600-A vacuum
vacuum, VCBs are very efficient at interrupting circuit breaker
fault currents. Figure 5.28 shows a 15.5-kV VCB.
Although VCBs have superior performance, there
is still a significant number of oil circuit breakers
(OCBs) installed in older substations. The oil in
an OCB serves to insulate between the phases,
insulate between phase and ground, and help to
extinguish the arc that occurs when the circuit
breaker contacts open.
SUBSTATIONS
(4) Fuses
Fuses are the oldest and simplest devices for sensing overloads or shorts circuits and
opening a circuit. Because fuses can be constructed with a wide variety of time-
current characteristics, they can be applied in many special situations. However, one
disadvantage of a fuse is that it is a one-shot device (i.e., when a fuse blows, it must
be replaced). For this reason, fuses are used primarily for transformer protection in
mining applications (see fuse location in Figure 5.27). Fuses are ideal for this
application because they are excellent at limiting the energy tothe transformer during
a short circuit, thereby limiting thermal and mechanical stress on the transformer
caused by high fault current.
(5) Disconnect Switches
Disconnect switches are used on the input and output primary and secondary to
disconnect power to or from the substation. Disconnect switches are constructed to
provide visual assurance that the circuit or device is disconnected from the source.
This visual assurance is essential to the safety of maintenance personnel who may be
working on substation components.
SUBSTATIONS
35kV
(6) Surge Arresters
Surge arresters are used to protect equipment from voltage transients due to
switching and lightning. They are connected from line to ground and exhibit high
resistance to normal operating voltages but low resistance to high voltages. This
characteristic causes surge arresters to divert abnormal surges to ground and
protect equipment from damaging voltages.
Surge arresters may be either gapped arresters with resistors made of silicon
carbide or metal oxide arresters without gaps. The silicon carbide arresters have an
air gap (or a series of gaps) in series with the silicon carbide. There is also a shunt
resistorconnected in parallel with each gap. During an overvoltage, the gaps spark
over and current is conducted through the silicon carbide. Silicon carbide arresters
are (reportedly) susceptible to moisture entry that can contaminate the gaps,
causing the arrester to fail because it sparks over at reduced voltage levels. Metal
oxide arresters use zinc oxide blocks with no gaps. It is believed that the failure
rate of metal oxide arresters is lower compared with silicon carbide arresters
because of the absence of spark gaps. Although there are many silicon carbide
arresters in service, most new applications utilize metal oxide arresters.
SUBSTATIONS
(7) Ground Beds and Neutral Grounding Resistor
The ground bed establishes the earth as the ground reference and the neutral
grounding resistor limits the fault current during a ground fault. A detailed description
of the ground bed(s) and neutral grounding resistor (NGR) are given later in the
“Grounding” section of this chapter.
(8) SWITCHHOUSES
A switchhouse is used to provide protective relaying to the distribution system and to
allow the system to branch. Switchhouses are typically single, double, or triple. As the
names imply, a single switchhouse has one protected outgoing circuit, whereas double
and triple switchhouses have two and three protected outgoing circuits, respectively.
Switchhouses with more than three protected outgoing circuits exist, but because of
space limitations underground, the use of switchhouses with more than three protected
outgoing circuits is probably limited to surface mines. In addition to the protected
circuits, it is common for a switchhouse to have a feed-through circuit, which is an
unprotected outgoing circuit, essentially a continuation of the incoming circuit.
SUBSTATIONS
(8) SWITCHHOUSES
Figure 5.29 shows a one-line diagram of a double switchhouse without a feed-

through circuit. Incoming high voltage enters the switchhouse through the input
receptacle to a feed-through receptacle (if present) and load break switch. The load
break switch has an external handle with a means for locking it in the open position.
This switch plus a viewing window provide visual assurance that the circuit is open.
Circuit protection devices include phase overcurrent and short-circuit relays (50/51)
and ground-fault relays (50-G). A ground-wire monitor for each protected outgoing
circuit is also included. As with substations, the circuit breakers in switchhouses are
usually VCBs.
Switchhouses also contain lid interlock switches along the side and top covers of
the switchhouse. The interlock switches are wired into the ground wire monitor
circuit (described later) such that they trip the upstream breaker when a lid is
removed. An emergency stop button is also wired into the ground wire monitor
circuit. Figure 5.30 shows a double switchhouse with one of the VCBs drawn out.
SUBSTATIONS
(8) SWITCHHOUSES
Figure 5.30 Double switchhouse
Figure 5.29 One-line diagram of switchhouse

POWER CENTERS
The primary function of a
power (or load) center is to
transform the distribution
voltage to utilization levels
and provide protected,
outgoing circuits for
machines and motors. In
many respects, a power
center is very similar to a
substation, and it could, in
many ways, be considered
to be a portable substation.
Figure 5.31 shows a
simplified one-line diagram
of a power center that
would be applied to
underground coal mining.
Observation of this figure
shows many similarities to
the substation one-line
POWER CENTERS
(1) Input Receptacle
Input to the power center is usually through a high-voltage cable coupler of special
construction. The coupler and receptacle are constructed so that the ground check
circuit is disconnected first, the power conductors disconnected second, and the
ground circuit disconnected last when the coupler is being disconnected from the
input receptacle. As with the switchhouse, the pilot contact is breaker. Consequently,
this arrangement causes the upstream breaker to trip if the coupler is disconnected
from the input receptacle while the circuit is energized. In addition, the ground
circuit is not broken until after the power circuit is broken, affording the highest
level of safety. (Note: The input and output receptacles of a switchhouse have the
same type of construction.)
(2) Load-Break Switch
The disconnect switch in a power center is typically a load-break switch that can be
used to disconnect power to the transformer primary. Load-break switches differ
from disconnect switches in that they are capable of interrupting currents equal to
their continuous current rating; therefore, they can be opened under load conditions.
For example, a typical load-break switch rated 15 kV and 600 A is designed to
interrupt 600 A. Figure 5.32 shows a vacuum load-break switch.
POWER CENTERS
Figure 5.32 Vacuum load-

break switch
(3) Fuses
As with a substation, fuses are used principally to protect the transformer. Fuse
selection is primarily based on having the fuse blow before damaging levels of fault
current flow but still permit transformer inrush currents without damaging the fuse
element. Based on these considerations, fuses should be able to withstand 12 times
the transformer rated current for 0.10 seconds without any element damage. In
addition, the fuse element should also be able to withstand 25 times the transformer
rated current for one half cycle without damage.
POWER CENTERS
(4) Surge Arresters
Surge arresters are typically located at the transformer primary terminals to protect
the transformer from damaging surges. Unlike surge arresters at the substation,
however, power center surge arresters. are connected from the power conductors to
the frame of the power center instead of the station ground bed. Surge arrester
selection is primarily based on the transformer basic impulse insulation level (BIL),
which is the transformer’s ability to withstand a voltage surge without damage. BIL
is referenced to a transient voltage that reaches its peak in 1.5 μs and decays to one
half of its peak value in 40 μs. (This characteristic is typical of the shape of surges
caused by lightning or switching.) The surge arrester should spark over well below
the transformer BIL to protect the transformer.
(5) Transformer
Power center transformers are typically dry-type transformers, unlike the oil-filled
transformers usually found in substations. Dry-type transformers used in power
centers are almost exclusively air cooled (although some may be sealed, gas-filled
units). The transformers may be two- or three-winding transformers. Three-winding
transformers are built to provide two utilization voltages and are common in
underground coal mining applications. For example, a typical power center may have
a 12,470-V primary, a 995-V (or 2,400-V) secondary for the continuous miner, and a
480-V tertiary for other equipment.
POWER CENTERS (6) Neutral Grounding Resistor
(5) Transformer The neutral grounding resistor is used to limit fault
current during a ground fault. A detailed discussion
of the neutral grounding resistor is given later in the
“Grounding” section of this chapter.
Figure 5.34 Arc chutes in a

circuit breaker
Figure 5.33 500-kVA Three-phase dry-type
transformer
POWER CENTERS
(7) Outgoing Circuits
Molded-case circuit breakers are normally used to protect each outgoing circuit.
Unlike oil-filled or vacuum breakers, molded-case circuit breakers have their
contacts in air and they must extinguish the arc that forms when the breaker contacts
separate. This is done through the use of specially designed arc chutes that break the
arc into a series of smaller arcs that are lengthened and cooled to extinguish the arc.
Figure 5.34 shows arc chutes in a circuit breaker.
The molded-case breakers often have both overload and short-circuit elements in
them instead of having separate relays that send a trip signal to the circuit breaker.
Short-circuit protection is achieved by having a solenoid in series with the load
current. The circuit breaker contacts are held closed by a latch; and when the latch is
released, the contacts open rapidly by spring action. When a short occurs, the high
current increases the magnetic pull of the solenoid, causing the latch to be released
and opening the circuit breaker contacts.
Each outgoing circuit also has ground-fault protection provided by a zero-
sequence relay. When a ground fault occurs and is detected, the zerosequence relay
sends a trip signal to the molded-case breaker. Ground wire monitoring is also
included on each outgoing circuit, as described later in the “Grounding” section.
Figure 5.35 shows two underground power centers.
POWER CENTERS
(7) Outgoing Circuits Figure 5.35 Underground power centers
A. Longwall Power Center
B. Continuous Miner Power Center

GROUNDING
A ground or ground system refers to a conducting connection by which an electric

circuit or equipment is connected to the earth, or some large conducting body that
serves in place of the earth. Grounding is used to establish and maintain the
potential of the earth on conductors connected to it (IEEE 142-2007). Systems and
circuit conductors are grounded to:
1. Limit voltages due to lightning, line surges, or unintentional contact with
higher voltage lines;
2. Stabilize the voltage during normal operation; and
3. Provide a low impedance path for fault current that will facilitate the operation
of overcurrent devices during ground-fault conditions.
Although not listed by the NEC, another important purpose of grounding is to reduce
electrical noise that can interfere with electronic equipment. Poor grounding practices could
affect communication and automation equipment.
An important function of equipment grounding is to maintain all metal equipment frames
at, or near, ground potential to minimize shock hazards to mine personnel. If done properly,
equipment will also be protected.
GROUNDING
(1) Types of Grounding Systems

The major types of grounding systems used in the mining industry include the ungrounded,
solidly grounded, and resistance-grounded systems. The three systems are shown in Figure
5.37a, b, and c, respectively, and their advantages and disadvantages are discussed in the
following paragraphs.
GROUNDING

GROUNDING

Figure 5.37 Common types of grounding systems

5. Mine Electrical Power GROUNDING
(2) Ground Wire Monitoring

Because grounding conductors are critical to the safe operation of power systems,
MSHA (America Mine safety and Health Administration)requires ground-check
circuits to continuously monitor the integrity of grounding conductors in coal mine
power systems. A monitor must cause its associated circuit breaker to trip if the
grounding conductor is broken. Ground-check monitors are divided into two general
classifications: impedance types and continuity types.
Figure 5.38 Impedance-type

ground-check monitor

Because grounding conductors are critical to the safe operation of power systems,
MSHA (America Mine safety and Health Administration)requires ground-check
circuits to continuously monitor the integrity of grounding conductors in coal mine
power systems. A monitor must cause its associated circuit breaker to trip if the
grounding conductor is broken. Ground-check monitors are divided into two general
classifications: impedance types and continuity types.
Figure 5.39 Continuity-type

ground-check monitor

Figure 5.40 illustrates another type of ground wire monitor that uses an audio signal
to check the continuity of the grounding conductor.
Figure 5.40 Ground wire monitor utilizing a

ground wire inductor
(3) Ground Beds
Adequate grounding has historically been difficult to achieve in the mining industry.
Problems arise because the mine is constantly expanding; therefore, the equipment
must be moved frequently. In addition, much of the mining machinery is portable,
making it difficult to establish a suitable ground near each machine. This situation is
further complicated because mine personnel are required to regularly come in
contact with portable machinery, thereby increasing shock hazards. Because of these
shock hazards and the difficulties in trying to establish local ground beds, the U.S.
Bureau of Mines recommended, in 1916, that the frames of mining equipment be
connected to a permanent ground bed located near the main substation.
The most important factor in establishing an adequate ground bed is the soil
resistivity. Because of its importance to ground beds, resistivity will be briefly
reviewed before discussing ground bed design.
(4) Ground Beds--- Station Ground Bed

The present recommended grounding practice for the mining industry (and a
requirement in coal mines) is to employ two separate ground beds: the station (or
system) ground bed and the safety ground bed. Each bed has distinctly different
functions and design requirements.
The primary purpose of the station bed is to protect personnel working within
and nearby the substation during normal operating conditions and also during
lightning strikes, short circuits, equipment failures, and situations of human error or
carelessness. This protection is achieved by maintaining a low-voltage gradient in
and around the substation, even during fault conditions. A secondary function of the
station ground bed is to limit the electrical stress on insulation by conducting
lightning strikes to the earth through surge arresters.
One of the most important characteristics of the station bed for achieving its
primary purpose is the arrangement of the ground mat itself. It is imperative that the
ground mat be designed to maintain a low-voltage gradient in and near the
substation during fault conditions so that any individual coming in contact with a
faulted component, or working near a faulted component, will not be exposed to
shock hazards.
Summary of this chapter
Mine electrical systems are critical to the coal mining industry. Much of the
surface equipment and most of the underground equipment are electrically
powered. In addition, equipment size and complexity have increased to meet
the production, productivity, and safety demands of the industry. For example,
all U.S. longwalls now operate at high voltage, either 2,400 V or 4,160 V, and
there is an increasing number of high-voltage (2,400-V) continuous miners
being purchased and put into service.
Because electrical equipment is constantly changing, the purpose of this
chapter has been to provide a foundation of mine power systems rather than
providing just a snapshot of mine electrical systems and equipment of today.
Consequently, the chapter has focused on three-phase power system analysis;
an overview of substations, switchhouses, load centers, and cables; and
grounding concepts. With this foundation, the interested reader can explore
more advanced topics of mine electrical systems.
The above is the main content
of Mine Electrical Power
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5.

Mine Electrical Power

Figure 5.1 Basic power system arrangement

The power supply voltage

Figure 5.2 Simple mine power system

Figure 5.3 Expanded

Figure 5.4 Primary loop distribution system

The application of electrical equipment in the mining industry is heavily regulated

(1) Cable Types

Figure 5.22 shows the relationships

Figure 5.22 Strand and insulation shielding

Figure 5.23 Typical high-

AWG = American wire gauge. MCM = Thousand circular mils.

Table 5.6 Typical power factor and

Table 5.10 Selected

(5) Disconnect Switches

Figure 5.29 shows a one-line diagram of a double switchhouse without a feed-

Figure 5.30 Double switchhouse

Figure 5.29 One-line diagram of switchhouse

Figure 5.32 Vacuum load-

Figure 5.34 Arc chutes in a

(7) Outgoing Circuits

(7) Outgoing Circuits Figure 5.35 Underground power centers

A. Longwall Power Center

B. Continuous Miner Power Center

A ground or ground system refers to a conducting connection by which an electric

(1) Types of Grounding Systems

(1) Types of Grounding Systems

(1) Types of Grounding Systems

Figure 5.37 Common types of grounding systems

(2) Ground Wire Monitoring

Figure 5.38 Impedance-type

(2) Ground Wire Monitoring

Figure 5.39 Continuity-type

(2) Ground Wire Monitoring

Figure 5.40 Ground wire monitor utilizing a

(3) Ground Beds

(4) Ground Beds--- Station Ground Bed

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