Electrical Safety in Mines

- by Anand Agrawal

DDMS (Electrical),

DGMS, South Central Zone,

Hyderabad.

Introduction:

With improved technology there has been extensive development of the

mining industry in recent years with greater emphasis on mechanisation
leading to wider use of electricity. Hence, an attempt is made herein, to
provide a handy and very practical aspects covering technical requirements
and proven practices for safe working in relation to electrical safety in mines.

Wherever electricity is utilised, there will always be the possibility of accident

due to conditions in the industry. In case of mines, it demands special
attention and care during the installation and maintenance of electrical
equipment due to lack of proper working space, poor environmental
conditions and frequent shifting of equipment.
If we analyse the major causes of the electrical accidents in mines it will be
seen that poor maintenance of electrical equipment,
malfunctioning/bypassing of the protective devices of controlling
switchgears, and also improper handling and supervision during
maintenance/installation/transportation of equipment contribute to a large
extent to the occurrence of electrical accidents. Further, the continued safety
of flame proof and intrinsically safe equipment in explosive atmosphere is as
much dependent on installation and maintenance as it is on the design.
The accidents due to electric hazards cannot be eliminated completely, if
and when they occur, either to oneself or ones colleagues until we have an
understanding of these hazards on the human body while dealing with any
electrical accidents in the mine.

Hazards of Electricity:

Every worker should always be aware that electricity is the single root cause
of all of the following injuries described and the worker should treat
electricity as the hazard and should always follow the safety regulations and
stipulated guidelines framed by this Directorate and by the Manufacturer.

Electrical hazards can be broadly classified into three components.

a) SHOCK: Electric shock is the physical stimulation that occurs when
electric current flows through the human body. Severity of electrical
shock mainly depends on the following factors.

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i. Physical condition and physical response: The physical condition of
the individual greatly influences the effects of current flow. A given
amount of current flow will usually cause less trauma to a person in
good physical condition. Moreover, if the victim of the shock has any
specific medical problems such as heart ailments will be severely
affected compared to a person with healthy heart.
ii. Current duration: The amount of energy delivered to the body is
directly proportional to the length of time that the current flows;
consequently, the degree of trauma is also directly proportional to
the duration of the time.
iii. Path of the current flow: Current flow through body tissues delivers
energy in the form of heat. If sufficient heat is delivered, tissue
burning and/or organ damage can occur. Note that the amount of
heat that is delivered is directly proportional to the duration of the
current.
iv. Effect of frequency: At higher frequencies, the effect of Joule heating
become less significant. Some differences are apparent even
between DC (Zero Hz) and standard power line frequencies (50Hz).
When equal current magnitudes are compared (DC to AC rms), DC
seems to exhibit two significant behavioural difference.
Victims of DC shock have indicated that they feel greater heating
from DC than from AC. The reason for this phenomenon is not
totally understood; however, it has been reported on many
occasions.
The DC current let go threshold seems to be higher than AC let
go threshold.
v. Effect of voltage magnitude: It was assumed that a 200-V source
would create the same amount of physical trauma that a 2000-V
source would assuming that the current magnitude is the same.
vi. Parts of the Body- Current flow affects the various bodily organs in
different manners. For example, the heart can be caused to fibrillate
with as little as 75 mA. The diaphragm and the breathing system can
be paralyzed, which possibly may be fatal without outside
intervention, with less than 30 mA of current flow.
vii. It takes a very low value of current flowing through the human body to cause death
or serious physical harm. The following chart illustrates average values of current
and the effects as taken from the published studies.

Current Effect
1 mA Barely perceptible
1-3 mA Perception threshold (most
cases)
3-9 mA Painful sensations
9-25 mA Muscular contractions (cant let

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 go)
25-60 mA Respiratory paralysis (may be
fatal)
60 mA or more Ventricular fibrillation (probably
fatal)
4 A or more Heart paralysis (fatal)

b) ARC: The heat and light energy release that is caused by the electrical
breakdown of and subsequent electrical discharge through an electrical
insulator such as air. Arcs can be initiated in several ways, such as

When the voltage between two points exceeds the dielectric

strength of the air. This can happen when over voltages due to
lightning strikes or switching surges occur.
When the air becomes superheated with the passage of current
through some conductor. For example, if a very fine wire is subjected
to excessive current, the wire will melt, superheating the air and
causing an arc to start.
When two contacts part while carrying a very high current.

The heat energy of an electrical arc can kill and injure personnel at
surprisingly large distances causing burn injuries which are thermal in
nature and, therefore, fall into one of the three classical categories:
First-degree burns. First-degree burning causes painful trauma to the
outer layers of the skin. Little permanent damage results from a first-
degree burn because all the growth areas survive. Healing is usually
prompt and leaves no scarring.
Second-degree burns. Second-degree burns result in relatively severe
tissue damage and blistering. If the burn is to the skin, the entire
outer layer will be destroyed. Healing occurs from the sweat glands
and/or hair follicles.
Third-degree burns. Third-degree burns to the skin result in complete
destruction of the growth centers. If the burn is small, healing may
occur from the edges of the damaged area; however, extensive third-
degree burns require skin grafting.

BLAST: When an electric arc occurs, it superheats the air instantaneously.

This causes a rapid expansion of the air with a wave front that can reach
very pressures of which is sufficient to explode switchgear, turn sheet metal
into shrapnel, turn hardware into bullets, push over concrete walls, and
propel molten metal at extremely high velocities. Sometimes an arc is not
accompanied by a blast, but when it is, it can be lethal. The pressures
developed by an electrical arc can be extremely high. One study noted that
copper, when vaporized, expands at a factor of 67,000 times which one
expert stated was the same expansion as dynamite. Doors or covers must be
securely latched before operating a switch or circuit breaker. Technicians or
operators must place their body in the safest position before operating the
equipment. Flash suits will protect against the flash/flame and incident
energy hazards of the arc-flash but may not protect against the pressures of

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the arc-blast. There are several issues to think about with an electrical arc-
flash and arc-blast:
Copper expanding when vaporized is similar to dynamite releasing:
- Dynamite releases energy in microseconds
- Arc releases energy in milliseconds
- 1 MW of power = 1 stick of dynamite (1/3 lb. of TNT)

An electrical arc is a multi-hazard event:

- Electrical Arc
- Flash/flame temperature
- Incident energy

Electrical Blast (explosion)

- Fragmented metal
- Molten metal
- Vaporized metal (plasma)
- Pressure

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 The following key points should always be kept in mind:
Workers may not assume that they are safe from electrical arc flash
events even though the access doors and panels are fully secured.
Unless it is specially designed FLP switchgear, metal-clad equipment
might not withstand the explosive force of an electrical blast.

Injuries due to electricity:

Injury from electrical hazard can come from both direct and indirect sources:
The reflex action caused by the passage of current flow can cause falls
resulting in cuts, abrasions, or broken limbs.
Nerve damage from shock or burns can cause loss of motor function,
tingling, and/or paralysis.
Burns, both thermal- and current-induced, can cause extremely long
duration and intensely painful suffering. Third-degree burns may
require skin grafting to heal.
The light intensity, molten metal and/or burns to the eyes can cause
blindness.
The concussion of a blast can cause partial or complete loss of hearing.
Current-induced burns to internal organs can cause organ dysfunction.
The superheated plasma may be inhaled, causing severe internal
burns.
Metal vapors may be inhaled filling the lungs with toxic residues.

If the electrical injury is severe enough, death can result.

Common causes of electrical accidents in mines:

If we analyze the causes of electrical accidents in mines, it will be seen that

poor maintenance of electrical equipment such as drills and mobile
machinery, malfunctioning of the protective devices of the feeder controlling
switches, starters, panels etc. and also improper handling and supervision
during installation & maintenance contribute to a large extent to the
occurrence of electrical accidents.

Further, attention is required to be paid to the following causes to prevent

occurrence of electrical accidents in mines.

Employment of unskilled and untrained work personnel for electrical

job in the mines.
Dual control of supervision and sometimes no supervision at all.
Absence of clear-cut instructions from Engineers/Supervisors to
workmen.
Lack of communication between work personnel and
Supervisors/Engineers regarding day-to-day condition of working of
electrical equipment at surface and in underground.
Non provision of tools, tackles and safety gadgets to workmen.

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 Non provision/adequate provision of materials for day-to-day and
breakdown maintenance of electrical equipment.
Lack of proper training from the level of workmen upto the level of
senior engineers who are responsible for installation, operation and
maintenance of electrical equipment in mines.
Lack of proper attitude and interpersonal cooperation at different
levels.
Casual and careless attitude while taking up an electrical job and utter
disregard to observance of basic norms already set for these type of
jobs.

Preventive measures and personal protective equipment (PPE) /

practices etc.
In this backdrop the Directorate and the Industry have adopted a pro-active
approach by issuing technical circulars and guidelines regarding code of safe
practices for handling electrical equipment in mines.

By far the safest way to work on electrical equipment and circuits is to de-
energize, lock, and tag them. Suitable warning signs shall be posted by the
individuals who are to do the work. Switches shall be locked out or other
measures taken which shall prevent the power circuits from being energized
without the knowledge of the individuals working on them. Such locks, signs,
or preventative devices shall be removed only by the person who installs
them or by authorized personnel.

The types of safety measures & personal protective equipment that may be
used to protect from each of the three electrical hazards are remarkably
similar which are summarized in the below Table.

Hazard Personal protective equipment Preventive SOPs

Shock Rubber insulating De-energize all circuits and
equipment including conductors in the immediate
gloves, sleeves, mats and work area.
covers. Develop and follow a
Insulated tools when lockout/ tagout procedure.
working near energized Maintain a safe working
conductors. distance from all energized
Arc Approved flash/flame- equipment and conductors.
resistant work clothing. Follow all safety procedures
Approved flash suits when and guidelines issued from
performing work with a high time to time by this
risk of arcing. Directorate and by
Use hot sticks to keep as Manufacturer.
much distance as possible. Carefully inspect all
Wear eye protection. equipment before
Wear rubber gloves with commissioning. This
leather protectors and/or includes tools, test
other flash-proof gloves. equipment, electrical
Blast Approved flash/flame- distribution equipment, and

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 resistant work clothing. This safety equipment.
will protect from splashed Make certain that all non-
molten material. energized equipment is
Wear face shields. properly grounded. This
applies to both normal
system grounding and
temporary safety grounds.

Note that the information given in the above table is general. Be aware that
any given strategy may not be applicable in a given situation.

Fundamentals of electrical protection for minimizing electrical

hazard:

All electrical circuits have a basic requirement that the conductors of the
electric current be of adequate size to carry normal and fault current loads
without being damaged or degraded by excessive heating. Furthermore, all
electric current conductors are required to be insulated to prevent unwanted
current flow from one conductor to another or from one or more conductors
to earth.
The purposes of protection devices are:
To detect excessive current levels in power system conductors;
To detect excessive current flows to earth due to insulation failure.
To confirm earth continuity.
These must be effected before energizing the equipment.

Every electrical circuit shall be provided with effective means of

automatically cutting off the power supply from that circuit in the event of
any of the following electrical fault occurring in that part of the circuit.
Instantaneous short circuit current
Overcurrent
Earth leakage/fault current
Overload
Over temperature; and
any other abnormal conditions.

All electrical equipment (including cables) shall be designed, installed,

commissioned, operated, maintained and decommissioned in such manner
as to control any risks from fire, explosion, electric shock or unintended
movement of equipment. In particular all mines electrical installations must
comply with the relevant provisions of Mines Act 1957, Electricity Act 2003
and Rules & Regulations framed therein.

It is important that coordination of protective devices shall be maintained

within any constraints placed in the mine installations. If protection devices

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fail to trip in a coordinated manner it can lead to unsafe fault finding,
resulting in restoration of power under fault conditions.
Further, effective earthing of electrical installations forms a vital role in
ensuring electrical safety. It serves following important basic requirements:
To provide a sufficiently secure low impedance path to allow circuit
protection to operate when required to clear faults resulting from an
insulation failure to earth
To limit touch voltages, transfer potentials and step voltages to a level
that is not dangerous.
Effective operation of protective devices incorporated with controlling
switchgears.

Details and methods of installation earthing shall be followed as given in IS:

3043-1987 (code of practice for earthing)

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CONCLUSION
In resolving the issues in electrical safety in the mining industry, a path must
be followed that will lead to a comprehensive analysis of the problems and
hazards that exist or may exist and provide a quantified value to ensure the
selection of appropriate personal protective equipment and clothing as well
as safe work practices and procedures. An analysis of all three hazards;
electrical shock, electrical arc-flash, and electrical arc-blast must be
completed and steps taken to prevent injuries and fatalities.

We can therefore conclude that it is not only by framing rules/regulations and

statutes that the electrical accidents in mines can be minimized, but also the
approach of the people towards their responsibilities has a great bearing on
reduction of accidents in mines. We will have to be proactive in our
approach and more responsible towards the objective of eliminating
accidents in our mines due to electricity.

Acknowledgement:
I would like to thank Shri S. K. Dutta, officiating DDG, South Central Zone, for
his kind permission to present this Paper. The views expressed herein are
my own and do not reflect the views of this Directorate.

References:
1. IS: 4051:1967 Code of Practice for installation and maintenance of
electrical installations in mines.
2. IS:3043:1987 Code of Practice for Earthing
3. IS:5216(1&2):1982 Recommendation on safety procedures and
practices in electrical work
4. NEC 2010
5. Electrical Safety Handbook, Third Edition, McGraw-Hill

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