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Sans10086 2

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© SABS.

This standard may reside on internal network or intranet on a Single Site only and is exclusively available to EHL Consulting Engineers (Pty) Ltd in
accordance with copyright exploitation agreement no. 014/009/23-098, valid until 2024-09-30. The single-site licence allows EHL Consulting Engineers (Pty) Ltd to
make five (5) printouts of the standard and will expire after one year unless renewed.

ISBN 978-0-626-27012-4
SANS 10086-2:2013
Edition 2

SOUTH AFRICAN NATIONAL STANDARD

The installation, inspection and maintenance

of equipment used in explosive atmospheres

Part 2: Electrical equipment installed

underground in mines

Warning — Can only be used

in conjunction with
SANS 10108.

Published by SABS Standards Division

1 Dr Lategan Road Groenkloof Private Bag X191 Pretoria 0001
Tel: +27 12 428 7911 Fax: +27 12 344 1568
www.sabs.co.za
© SABS

This product is copyrighted by SABS, 1 Dr Lategan Road, Groenkloof, 0181, South Africa. All rights reserved.
© SABS. This standard may reside on internal network or intranet on a Single Site only and is exclusively available to EHL Consulting Engineers (Pty) Ltd in
accordance with copyright exploitation agreement no. 014/009/23-098, valid until 2024-09-30. The single-site licence allows EHL Consulting Engineers (Pty) Ltd to
make five (5) printouts of the standard and will expire after one year unless renewed.

SANS 10086-2:2013
Edition 2

Table of changes
Change No. Date Scope

Foreword
This South African standard was approved by National Committee SABS TC 65, Explosion
prevention, in accordance with procedures of the SABS Standards Division, in compliance with
annex 3 of the WTO/TBT agreement.

This document was published in February 2013.

This document supersedes SANS 10086-2:2006 (edition 1).

SANS 10086 consists of the following parts, under the general title: The installation, inspection and
maintenance of equipment used in explosive atmospheres:

Part 1: Installations including surface installations on mines.

Part 2: Electrical equipment installed underground in mines.

Part 3: Repair and overhaul of equipment.

Reference is made in 3.1.1 to the "national accreditation body". In South Africa this is The South
African National Accreditation System (SANAS).

Reference is made to “legislation”, “regulations”, “statutory notices”, "statutory requirements" and

"statutory regulations" in this document. In South Africa this means, as appropriate, the Mine Health
and Safety Act, 1996 (Act No. 29 of 1996), the Mineral Act, 1991 (Act No. 50 of 1991), the
Occupational Health and Safety Act, 1993 (Act No. 85 of 1993), and the Explosives Act, 2003 (Act
No. 15 of 2003), and the Regulations to these Acts.

Annexes A, B and I form an integral part of this document. Annexes C, D, E, F, G, H and J are for
information only.

SANS 10086-2:2013
Edition 2

Introduction
The purpose of this part of SANS 10086 is to assist the users of explosion-protected electrical
equipment in the installation, inspection and maintenance of electrical equipment in explosive
atmospheres underground in mines.

A further purpose of this part of SANS 10086 is to provide guidance to manufacturers of explosion-
protected equipment and machinery on the design of such equipment.

Hazardous areas of a general nature on the surface of mining applications, for example, petrol
bowsers, paint spray booths, commercial fuel storage pumps, crushing and screening plants etc.,
are covered in SANS 10086-1.

Any work performed on electrical equipment installed underground in mines should be carried out
with due reference to the mine-specific hazard identification and risk assessment of equipment and
its installation.

SANS 10086-2:2013
Edition 2

This page is intentionally left blank

SANS 10086-2:2013
Edition 2

Contents
Page

Foreword

Introduction................................................................................................................................. 1

1 Scope .................................................................................................................................... 5

2 Normative references............................................................................................................ 5

3 Definitions and abbreviations................................................................................................ 7

4 General ................................................................................................................................. 18
4.1 Zones ......................................................................................................................... 18
4.2 Classification .............................................................................................................. 18
4.3 Selection..................................................................................................................... 18
4.4 Documentation ........................................................................................................... 20
4.5 Qualifications and training.......................................................................................... 21

5 Installation ............................................................................................................................. 21
5.1 General ........................................................................................................................ 21
5.2 Electrical protection and control techniques for switchgear and panels ...................... 22

6 Inspection.............................................................................................................................. 30
6.1 General ....................................................................................................................... 30
6.2 Types of inspection ...................................................................................................... 30
6.3 Grades of inspection .................................................................................................... 30
6.4 Moveable equipment.................................................................................................... 31
6.5 Conditions of use ......................................................................................................... 31
6.6 Internal faults in flameproof enclosures ....................................................................... 31
6.7 Intrinsically safe systems ............................................................................................. 32
6.8 Earth leakage testing ................................................................................................... 32
6.9 Coal dust on explosion-protected equipment .............................................................. 33

7 Maintenance ........................................................................................................................ 33
7.1 General ........................................................................................................................ 33
7.2 Test equipment ............................................................................................................ 34
7.3 Flameproof joints ......................................................................................................... 34
7.4 Fasteners and tools ..................................................................................................... 34
7.5 Use of solvents for cleaning......................................................................................... 34
7.6 Modifications and repairs ............................................................................................. 34
7.7 Isolation of circuits other than instrinsically safe circuits ............................................. 35
7.8 Light alloys ................................................................................................................... 35
7.9 Electromagnetic radiation, electromagnetic compatability (EMC),
electromagnetic interference (EMI),............................................................................. 35
7.10 Environmental conditions............................................................................................. 36

8 Specific types of protection ................................................................................................... 37

8.1 Intrinsically safe Ex i systems .................................................................................. 37
8.2 Flameproof protection Ex d ....................................................................................... 42
8.3 Increased safety Ex e................................................................................................ 43
8.4 Double protected........................................................................................................ 43

SANS 10086-2:2013
Edition 2

Contents (continued)

Page

9 Specific equipment................................................................................................................ 43
9.1 Flameproof transformers........................................................................................... 43
9.2 Flameproof switchgear.............................................................................................. 48
9.3 Flameproof electric motors......................................................................................... 54
9.4 Variable speed drives (VSDs) .................................................................................... 56
9.5 Lighting and luminaires .............................................................................................. 59
9.6 Electric cables ............................................................................................................ 61
9.7 Couplers and connectors ........................................................................................... 68
9.8 Intrinsically safe equipment or systems ..................................................................... 69
9.9 Battery bays ............................................................................................................... 73
9.10 Earthing systems........................................................................................................ 76
9.11 Communication equipment ........................................................................................ 85
9.12 Hand-held portable equipment................................................................................... 87
9.13 Moveable electrical equipment................................................................................... 87

Annex A (normative) Live testing in hazardous areas............................................................... 95

Annex B (normative) Insulation testing of cables in hazardous areas ...................................... 96

Annex C (informative) Main parameters that affect the frequency of inspections..................... 98

Annex D (informative) The control of Ex equipment.................................................................. 99

Annex E (informative) Typical inspection procedure for periodic inspections ........................... 102

Annex F (informative) Typical inspection schedules ................................................................. 103

Annex G (informative) Typical in-process risk assessment ...................................................... 107

Annex H (informative) Typical task observation or written safe work procedure ..................... 109

Annex I (normative) Safety precautions (lock-out procedurees, gas testing, NER tests) ......... 112

Annex J (informative) IEC scope for certified person scheme ................................................. 114

Bibliography.............................................................................................................................. 115

SANS 10086-2:2013
Edition 2

The installation, inspection and maintenance of equipment used in

explosive atmospheres

Part 2:
Electrical equipment installed underground in mines

1 Scope
1.1 This part of SANS 10086 covers the installation, inspection and maintenance of electrical
equipment used underground in mining applications where atmospheres might be explosive owing
to the presence of gases and dusts that are flammable in the presence of atmospheric oxygen.

1.2 This part of SANS 10086 does not cover the risks that arise from the toxicity of flammable
substances or their reaction products, nor does it cover explosives.

2 Normative references
The following referenced documents are indispensable for the application of this document. For
dated references, only the edition cited applies. For undated references, the latest edition of the
referenced document (including any amendments) applies. Information on currently valid national
and international standards can be obtained from the SABS Standards Division.

2.1 Standards
ARP 0108, Regulatory requirements for explosion-protected apparatus.

AS/NZS 2081, Electrical protection devices for mines and quarries.

BS 3101, Specification for control and interlock circuits primarily associated with flameproof
restrained plugs and sockets for use in coal mines.

BS 7202, Specification for non-incendive low voltage control/interlock and low voltage earth fault
monitoring circuits for use in mines.

SANS 97, Electric cables – Impregnated paper-insulated metal-sheathed cables for rated voltages
3,3/3,3 kV to 19/33 kV (excluding pressure assisted cables).

SANS 808, Cable glands for use on flameproof enclosures (Ex d).

SANS 1339, Electric cables – Cross-linked polyethylene (XLPE) insulated cables for rated voltages
3,8/6,6 kV to 19/33 kV.

SANS 10086-2:2013
Edition 2

SANS 1489-1, Electrical connectors in group I and group II hazardous areas – Part 1: General
requirements for group I hazardous areas.

SANS 1489-2, Electrical connectors in group I and group II hazardous areas – Part 2: Restrained
type plugs and sockets for group I hazardous areas.

SANS 1489-3, Electrical connectors in group I and group II hazardous areas – Part 3: Bolted type
plugs and sockets for group I hazardous areas.

SANS 1507-1, Electric cables with extruded solid dielectric insulation for fixed installations
(300/500 V to 1 900/3 300 V) – Part 1: General.

SANS 1507-2, Electric cables with extruded solid dielectric insulation for fixed installations
(300/500 V to 1 900/3 300 V) – Part 2: Wiring cables.

SANS 1507-3, Electric cables with extruded solid dielectric insulation for fixed installations
(300/500 V to 1 900/3 300 V) – Part 3: PVC Distribution cables.

SANS 1507-4, Electric cables with extruded solid dielectric insulation for fixed installations
(300/500 V to 1 900/3 300 V) – Part 4: XLPE Distribution cables.

SANS 1507-5, Electric cables with extruded solid dielectric insulation for fixed installations
(300/500 V to 1 900/3 300 V) – Part 5: Halogen-free distribution cables.

SANS 1507-6, Electric cables with extruded solid dielectric insulation for fixed installations
(300/500 V to 1 900/3 300 V) – Part 6: Service cables.

SANS 1520-1, Flexible electric trailing cables for use in mines – Part 1: Low-voltage (640/1 100 V
and 1 900/3 300 V) cables.

SANS 1520-2, Flexible electric trailing cables for use in mines – Part 2: High-voltage (3,8/6,6 kV to
19/33 kV) cables.

SANS 10012, The use of light metals in hazardous locations at mines.

SANS 10086-3, The installation, inspection and maintenance of equipment used in explosive
atmospheres – Part 3: Repair and overhaul of equipment.

SANS 10108, The classification of hazardous locations and the selection of apparatus for use in
such locations.

SANS 10114-1, Interior lighting – Part 1: Artificial lighting of interiors.

SANS 10119, Reduction of explosion hazards presented by electrical equipment – Segregation,

ventilation and pressurization.

SANS 10142-1, The wiring of premises – Part 1: Low-voltage installations.

SANS 60079-0/IEC 60079-0, Explosive atmospheres – Part 0: Equipment – General requirements.

SANS 60079-1/IEC 60079-1, Explosive atmospheres – Part 1: Equipment protection by flameproof

enclosures "d".

SANS 10086-2:2013
Edition 2

SANS 60079-11/IEC 60079-11, Explosive atmospheres – Part 11: Equipment protection by intrinsic
safety "i".

SANS 60079-31/IEC 60079-31, Explosive atmospheres – Part 31: Equipment dust ignition
protection by enclosure "t".

SANS 60529/IEC 60529, Degrees of protection provided by enclosures (IP Code).

SANS 60947-1/IEC 60947-1, Low-voltage switchgear and controlgear – Part 1: General rules.

SANS 60947-4-1/IEC 60947-4-1, Low-voltage switchgear and controlgear – Part 4-1: Contactors
and motor-starters – Electromechanical contactors and motor-starters.

SANS 61241-0/IEC 61241-0, Electrical apparatus for use in the presence of combustible dust –
Part 0: General requirements.

SANS 61241-2-1/IEC 61241-2-1, Electrical apparatus for use in the presence of combustible dust –
Part 2: Test methods – Section 1: Methods for determining the minimum ignition temperatures of
dust.

SANS 62444/IEC 62444, Cable glands for electrical installations.

2.2 Other publication

Title 30, Chapter 1. (30 CFR). Code of Federal Regulations. Available from World Wide Web
<www.gpoaccess.gov/cfr/index.html>.

3 Definitions and abbreviations

For the purposes of this document, the following definitions and abbreviations apply.

3.1 Definitions
3.1.1
accredited test laboratory
test laboratory that is accredited by the national accreditation body (see foreword) and appointed by
the approving authority (see 3.1.3) to carry out tests specified in the appropriate standards and to
issue IA certificates for explosion-protected equipment indicating that such equipment complies with
safety requirements and any other requirements of the approving authority

3.1.2
actual earth potential
potential of the electrical earthing system if lightning or another discharge occurs on the electrical
earthing system

3.1.3
approving authority
appropriate approving authority within the scope of the relevant legislation (see foreword)

SANS 10086-2:2013
Edition 2

3.1.4
associated electrical equipment
electrical equipment that contains both intrinsically and non-intrinsically safe circuits and that is so
constructed that the non-intrinsically safe circuits cannot adversely affect the intrinsically safe
circuits

NOTE Associated electrical equipment could be

a) electrical equipment that has a type of protection listed in this part of SANS 10086 for use in the appropriate
explosive gas atmosphere, or

b) electrical equipment that is not intrinsically safe and that should not be used within an explosive gas
atmosphere (for example, a recorder that is not situated in an explosive gas atmosphere, but is connected
to a thermocouple situated within an explosive atmosphere where only the recorder input circuit is
intrinsically safe).

3.1.5
back tripping
facility that allows a switch that feeds an item of equipment, local and remote from the equipment, to
be tripped if certain conditions arise

3.1.6
bonding
connecting together of the metal parts of individual equipment to prevent potential differences
occurring between them and thereby eliminating the risk of sparking or of electric shock

3.1.7
clearance
shortest distance in air between two conductive parts

3.1.8
close inspection
inspection that encompasses those aspects covered by a visual inspection on the external condition
of the equipment while in an energized state and, in addition, that identifies those defects

NOTE 1 Examples of defects are loose bolts which will be apparent only when access equipment is used, for
example, steps, step ladders (where necessary), and tools.

NOTE 2 Close inspections do not normally require the enclosure to be opened or the equipment to be
de-energized.

3.1.9
competent person
person who (in accordance with the relevant legislation (see foreword))

a) is qualified by virtue of his knowledge, training, skills and experience to organize the work and its
performance;

b) is familiar with the provisions of legislation and regulations (see foreword) which apply to the
work to be performed;

c) has been trained to recognize any potential danger or actual danger to health or safety in the
performance of the work; and

d) is in possession of an appropriate certificate of competency where such certificate is required by

the regulations (see foreword)

SANS 10086-2:2013
Edition 2

3.1.10
conducting parts
equipment capable of conducting electric current

NOTE Such equipment includes conveyor structures, pipelines, cable armouring or cable screens and rail
tracks.

3.1.11
corona
luminous discharge due to ionization of the air that surrounds a conductor, caused by a voltage
gradient that exceeds a certain critical value

3.1.12
countable fault
fault that occurs in parts of intrinsically safe electrical equipment that comply with the constructional
requirements of SANS 60079-11

3.1.13
creepage distance
shortest distance, along the surface of an insulating medium in contact with air, between two
conductive parts

3.1.14
de-energize
action that renders equipment safe to work on by effectively disconnecting it from all possible
sources of energy

3.1.15
degree of ingress protection of enclosures
IP code

extent to which measures are applied to an enclosure of electrical equipment to provide for

a) the protection of persons against inadvertent contact with, or approach to, live parts and against
contact with moving parts (other than smooth rotating shafts and the like) inside the enclosure,
and

b) the protection of equipment inside the enclosure against the ingress of solid foreign bodies and
the harmful ingress of water and dust

3.1.16
detailed inspection
inspection that encompasses those aspects covered by a close inspection and that focuses on the
internal condition of the equipment while in a de-energized state
NOTE In a detailed inspection those defects (for example, loose terminations) can be identified which will only
be apparent when the enclosure is opened, or when, where necessary, tools and test equipment (or both) are
used.

3.1.17
earthed system
system in which the neutral point of the transformer or the neutral earthing compensator is
connected either solidly or resistively through an impedance to the general mass of earth

3.1.18
earth fault current
fault current that flows to earth

SANS 10086-2:2013
Edition 2

3.1.19
earth path impedance
impedance between the electrical system earth and the true earth potential of the general mass of
earth

3.1.20
earth path resistance
resistance between the electrical system earth and the true earth potential of the general mass of
earth

3.1.21
equipotential
at the same potential or the same voltage

3.1.22
exothermic welding
process where two or more metallic parts (normally conductors) are joined together inside a
removeable mould, by using a compound (exothermic compound) (normally a powder) that results
in a solid conductive casting around the ends of the metallic parts

NOTE The term "exothermic" indicates a chemical reaction where heat is produced.

3.1.23
explosion protected
explosion protected equipment
descriptive of electrical equipment designed and approved for use in hazardous areas, in
accordance with a suitable protection method, including Ex d, Ex i, Ex e, Ex p, Ex n, Ex s, Ex m and
Ex q

NOTE 1 Some of the protection methods also apply to mechanical equipment, for example, flameproof
compression-ignition engines (diesel engines).

NOTE 2 The term "Ex N" instead of "Ex n" was used in some older standards.

NOTE 3 The term “explosion protected” is the process applied to equipment with the result that equipment
has become explosion protected.

3.1.24
explosion-protected technique
defined design technique used for preventing equipment from causing an explosion in a hazardous
area

3.1.25
explosive atmosphere
mixture under atmospheric conditions, of flammable substances in the form of gas or vapour or mist
or dust or fibre or flyings (or all of these) with air, in which, after ignition, combustion spreads
throughout the whole mixture

NOTE In coal mines the flammable gases most commonly present are methane and hydrogen.

3.1.26
flicker
fundamental cyclic variation of 100 Hz that is present in the light emitted by discharge lamps that
operate on the normal 50 Hz a.c. supply

SANS 10086-2:2013
Edition 2

3.1.27
gate-end box
type of explosion-protected assembly (flameproof switchgear) typically made up of two or more
compartments which house busbars, circuit-breakers, contactors, overcurrent, earth leakage and
pilot protection relays and indicating lights

NOTE 1 This type of switchgear is commonly found in close proximity to a working face in a coal mine where
there can be more than one gate-end box which makes up a bank.

NOTE 2 A gate-end box feeds power to mining equipment through trailing cable, plug and socket
arrangements.

3.1.28
glare
discomfort or impairment of vision experienced when parts of the visual field are excessively bright
in relation to the general surroundings

3.1.29
hazardous area
hazardous location
area determined in accordance with national regulations (see foreword) or in accordance with the
risk assessment of the plant or mine, where there might be a significant risk of the ignition of gas,
dust or vapour

NOTE For hazardous areas (locations) in mines, see SANS 10108.

3.1.30
ignition temperature of a dust layer
lowest temperature of a hot surface at which ignition occurs in a dust layer of specified thickness on
the hot surface

NOTE The ignition temperature of a dust layer can be determined by the test method given in
SANS 61241-2-1.

3.1.31
ingress protection
IP code
coding system to indicate the degree of protection provided by an enclosure against the ingress of
solid foreign objects, water and dust and to give additional information in connection with such
protection

NOTE See SANS 60529 for more information.

3.1.32
inspection
action that comprises careful examination of an item carried out either without dismantling or with
partial dismantling, as required, supplemented by means of the use of measurement instruments, in
order to arrive at a reliable conclusion as to the condition of the item

3.1.33
intrinsically safe circuit
Ex i circuit
circuit in which any spark, arc or thermal effect, whether produced normally (that is, by breaking or
closing of the circuit) or accidentally (for example, by a short-circuit or an earth fault), is incapable,
under prescribed test conditions, of causing ignition of a prescribed gas or vapour

SANS 10086-2:2013
Edition 2

3.1.34
intrinsically safe electrical equipment of categories ia, ib and ic
electrical equipment that is incapable of causing ignition under the following test conditions and
when the following safety factors are applied to the current or voltage (see SANS 60079-11):

Category Condition
ia Up to two countable faults applied
ib Up to one countable fault applied
ic Only non-countable faults applied

NOTE 1 Countable faults are those that occur in parts of the electrical equipment or system that are of
intrinsically safe design.

NOTE 2 Non-countable faults are those that occur in parts of the electrical equipment or system that are not
of intrinsically safe design.

3.1.35
intrinsically safe system
Ex i system
system that comprises electrical equipment and interconnecting wiring in which any spark or
thermal effect in any part of the system intended for use in a hazardous area is incapable, under
prescribed test conditions, of causing ignition of a prescribed gas or vapour

NOTE An intrinsically safe system is also incapable of igniting atmospheres that contain prescribed
flammable dusts or fibres.

3.1.36
intumescence
swelling of a substance as a result of exposure to heat, thus increasing in volume and decreasing in
density

NOTE Intumescences are typically endothermic as they can contain chemically bound water.

3.1.37
isolate
de-energize and, in the open position, comply with the distance between contacts specified for the
isolation function

3.1.38
maintenance
combination of actions carried out to retain an item in, or restore it to, conditions in which it is able to
comply with the requirements of the relevant standard and perform its design functions

3.1.39
maximum external inductance
Lo
maximum value of inductance in an intrinsically safe circuit that can be connected to the connection
facilities of the equipment without invalidating intrinsic safety

SANS 10086-2:2013
Edition 2

3.1.40
maximum external inductance to resistance ratio
Lo/Ro
maximum value of the ratio of inductance (Lo) to resistance (Ro) of any external circuit that can be
connected to the connection facilities of the electrical equipment without invalidating intrinsic safety

3.1.41
maximum input current
Ii
maximum current (peak a.c. or direct current (d.c.)) that can be applied to the connection facilities of
the intrinsically safe equipment

3.1.42
maximum input power
Pi
maximum power in an external intrinsically safe circuit that can be applied to the connection
facilities of the equipment

3.1.43
maximum input voltage
Ui
maximum voltage (peak a.c. or d.c.) that can be applied to the connection facilities of the
intrinsically safe equipment without invalidating intrinsic safety

3.1.44
maximum internal capacitance
Ci
total equivalent internal capacitance of the equipment, which is considered as appearing across the
connection facilities of the equipment

3.1.45
maximum internal inductance
Li
total equivalent internal inductance of the equipment, which is considered as appearing at the
connection facilities of the equipment

3.1.46
maximum internal inductance to resistance ratio
Li/Ri
maximum value of the ratio of inductance (Li) to resistance (Ri) which is considered as appearing at
the external connection facilities of the electrical equipment

3.1.47
maximum output current
Io
maximum current (peak a.c. or d.c.) in an intrinsically safe circuit that can be taken from the
connection facilities of the equipment

3.1.48
maximum output power
Po
maximum electrical power in an intrinsically safe circuit that can be taken from the equipment

SANS 10086-2:2013
Edition 2

3.1.49
maximum output voltage
Uo
voltage (peak a.c. or d.c.) in an intrinsically safe circuit that can appear under open circuit conditions
at the connection facilities of the equipment at any applied voltage up to the maximum voltage,
including Um and Ui

NOTE Where there is more than one applied voltage, the maximum output voltage is the voltage that occurs
under the most onerous combination of applied voltages.

3.1.50
maximum r.m.s. a.c. voltage or d.c. voltage
Um
maximum voltage that can be applied to the non-intrinsically safe parts of associated equipment
without invalidating intrinsic safety

3.1.51
maximum surface temperature
highest temperature attained in service under the most adverse conditions (but within the specified
tolerances) by any surface of electrical equipment which would be able to produce ignition of the
coal dust layer

NOTE 1 The most adverse conditions include recognized overload and any fault conditions recognized in the
specific standard for the type of protection concerned.

NOTE 2 Electrical equipment is classified into temperature classes T1 to T6 according to its maximum
surface temperature (see SANS 60079-0).

3.1.52
modification
change to the design of the equipment, which affects material, fit, form, function, or safety

3.1.53
neutral earthing compensator
Z winding used on a delta secondary winding of a transformer in order to provide an artificial neutral
point to enable the connection between the transformer and system earth

3.1.54
neutral earthing resistance
resistance of known value and rating installed in series with the transformer neutral to the earth
connection for the purpose of limiting the circulating earth fault current in the event of an earth fault
that occurs on the transformer secondary circuit

3.1.55
neutral earthing resistance monitoring system
NERM system
system whereby a neutral to earth resistance monitor or NERM relay is connected across the
neutral to earth path where a neutral resistor is installed, to ensure that the resistor is intact and in
circuit

3.1.56
neutral earthing resistor
NER
resistor that is installed between the neutral connection of the transformer and the substation earth
mat and serves to limit the current that flows to earth as a result of an earth fault on the system

SANS 10086-2:2013
Edition 2

3.1.57
non-countable fault
fault that occurs in part of intrinsically safe electrical equipment that does not comply with the
constructional requirements of SANS 60079-11

3.1.58
normal operation
operation of equipment that complies electrically and mechanically with the design standard and is
used within the limits specified by the manufacturer

NOTE Normal operation includes the application of Um from unspecified equipment.

3.1.59
operating voltage
voltage at which the connected load operates, and which is within the designed limits above or
below the rated voltage

3.1.60
pilot circuit protection
pilot circuits that monitor the continuity of the earth of a cable, so that interruption of the earth return
conductor will result in the immediate tripping of the power supply

NOTE The pilot circuit can also be used to provide a local or remote STOP/START facility.

3.1.61
repair
to restore faulty equipment to fully serviceable condition, in compliance with the relevant original
standard

3.1.62
sealing ring
elastic part of a cable gland, which serves to provide the clamping mechanism (for non-armoured
cables), the flame path, or the IP rating (or both)

3.1.63
short circuit
instance when two or more uninsulated phase conductors of a single or three-phase alternating
current supply make contact and results in a release of electrical energy

3.1.64
simple equipment
electrical component or combination of components of simple construction with well defined
electrical parameters, which is compatible with the intrinsic safety of the circuit in which it is used

3.1.65
soil resistivity
specific resistance of soil
resistance between the opposite faces of a cube of soil that have sides 1 m apart, expressed in
ohm metres (Ωm)

3.1.66
stroboscopic effect
effect caused by flicker in discharge lamps, so that smooth motion appears discontinuous or, in the
case of cyclical motion, stationary

SANS 10086-2:2013
Edition 2

3.1.67
temperature class
T rating
one of six values of temperature allocated to electrical equipment derived from a system of
classification according to the maximum surface temperature of the equipment

NOTE The six temperature classes are the following:

Maximum surface
T class temperature
o
C
T1 450
T2 300
T3 200
T4 135
T5 100
T6 85

3.1.68
true earth potential
potential of the general mass of earth which, in electrical terms, is taken to be zero volts

3.1.69
type of Ex protection
specific measures applied to electrical equipment to avoid ignition of a surrounding explosive gas
atmosphere

NOTE The different types of protection for electrical equipment are defined in SANS 10108.

3.1.70
vent
opening in an enclosure that has been deliberately introduced to allow breathing, venting, or the
drainage of water formed by condensation

3.1.71
visual inspection
inspection of the external condition of the equipment in an energized state, without the use of
access equipment or tools

NOTE Missing bolts, which would be apparent to the eye, is a possible defect that could be detected by visual
inspection.

3.1.72
volatile flammable liquid
flammable liquid that is stored, processed or handled at a temperature at or above its closed-cup
flash point

NOTE See SANS 10108.

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3.1.73
voltage range
numeric values for voltages between prescribed upper and lower limits

NOTE 1 The following voltage ranges apply:

Low-voltage LV Below 1 100 V

Medium-voltage MV 1 100 V to 44 kV
High-voltage HV >44 kV to 275 kV

NOTE 2 The primary and secondary terminals of a transformer should always have the relevant nominal
voltage indicated by a legible sign and not just "LV" and "HV". The primary voltage is normally higher than the
secondary voltage; this is known as a "step-down" transformer.

NOTE 3 Old transformers will be marked LT (below 1 100 V) and HT (1 100 V to 44 kV).

3.1.73.1
open circuit voltage
output voltage under no-load conditions depending on the regulation of the incoming supply

3.1.73.2
operating voltage
voltage at which the connected load operates within the designed limits above or below the rated
voltage

3.1.73.3
overvoltage
voltage that is applied to the equipment, and exceeds the rated voltage

3.1.73.4
rated voltage
voltage for which the equipment is designed, and the value is indicated on the equipment

3.1.73.5
undervoltage
voltage that is applied to the equipment, and is lower than the rated voltage

3.2 Abbreviations
ECM earth continuity monitor

EMC electromagnetic compatibility

HRC high rupturing capacity

HV high voltage

IA Inspection Authority

IT information technology

LV low voltage

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MV medium voltage

NER neutral earthing resistor

NERM neutral earthing resistance monitoring

OEM original equipment manufacturer

PE polyethylene

PLC programmable logic controller

PPE personal protective equipment

PWM pulse width modulation

r.m.s root mean square

SCADA supervisory control and data acquisition

VSD variable speed drives

4 General
4.1 Zones
To facilitate the selection of appropriate electrical and mechanical equipment and the design of
installations in explosive atmospheres, hazardous areas are divided into zones, depending on the
nature of the flammable substances and the frequency and duration of occurrences of hazards.

4.2 Classification

4.2.1 SANS 10108 gives definitions of the various zones and deals with the classification of
hazardous areas.

4.2.2 Electrical equipment should, as far as possible, be located in non-hazardous areas. If this is
not possible, the equipment should be located in the least hazardous area.

4.2.3 Hazardous areas can be limited in extent by construction measures, for example, walls or
dams. Ventilation or the application of protective gas can reduce the probability of the presence of
an explosive gas atmosphere so that areas of greater hazard can be transformed into areas of
lesser hazard or into non-hazardous areas (see SANS 10119).

4.3 Selection

4.3.1 The selection of the appropriate explosion protection technique for a particular classified
area shall be done in accordance with SANS 10108, and the equipment used shall be certified in
accordance with the requirements of SANS 10108.

4.3.2 All electrical equipment shall be tested and certified for use in a hazardous area (see 3.1.1).
The buyer and installer or user (or both) shall ensure that the equipment is covered by an IA

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certificate that clearly states the suitability for the application and the environment (for example,
methane and coal dust), and that the explosion protection rating on the IA certificate is suitable for
the gasses present.

NOTE The most common explosion-protection techniques found on mines are Ex d and Ex i, and to a lesser
extent Ex e.

4.3.3 Unless specifically designed as such, explosion-protected equipment is not waterproof or

sealed against the ingress of water and humid air. Users shall consider the possibility of water
falling from the roof or pools of water on the floor when the area or operation of explosion-protected
equipment is being considered. Ingress of water or moisture can lead to catastrophic failure of
equipment.

4.3.4 The international IP (ingress protection) rating system provides a two-digit code for
classifying the degrees of protection against ingress of solid objects, dust and water afforded by
electrical equipment and enclosures. The system is described in SANS 60529, and table 1 gives an
explanation of the numbers.

Table 1 — IP ratings

1 2 3 4
Protection against
First Protection against ingress Second
ingreass of
number of solid objects, number
liquids,
IP test IP
test
0 Non-protected 0 Non-protected
1 Protected against solid foreign 1 Protected against vertically
objects of 50 mm Ø and falling water drops
greater
2 Protected against solid foreign 2 Protected against vertically
objects of 12,5 mm Ø and falling water drops when
greater enclosure is tilted up to 15°
from the vertical
3 Protected against solid foreign 3 Protected against spraying
objects of 2,5 mm Ø and water
greater
4 Protected against solid foreign 4 Protected against
objects of 1,0 mm Ø and splashing water
greater
5 Dust-protected 5 Protected against water
jets
6 Dust-tight 6 Protected against powerful
water jets
7 Protected against the
effects of temporary
immersion in water
8 Protected against the
effects of continuous
immersion in water
NOTE The term "dust tight" is a misnomer and should not be used. It supposedly refers
to two other concepts, i.e. limited protection against dust ingress (no harmful effects) and
total protection against dust ingress

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4.4 Documentation
The following information shall be up to date and available:

a) identification of hazardous areas on the mine by means of a mine plan;

b) information on equipment protection groups and temperature classes;

c) applicable Ex certification documentation;

d) sufficient recommendations or manuals to enable the explosion-protected equipment to be

maintained in accordance with its type of protection (for example, a list of equipment with clear
indication of the location of the equipment and spares, and technical information, where
required);

e) guidelines for the compilation of a mandatory code of practice on trackless mobile machinery;

f) instructions for equipment, as required in SANS 60079-0;

g) the route of MV cables and positions of substations underground, shown on the mine plan;

h) a means to identify the location of a disconnecting point for any mobile installation;

i) a means of identifying the position of any substation underground with relation to all other
substations;

j) a MV reticulation single line diagram (SLD);

k) a code of practice (COP) prepared in accordance with regulations (see foreword) and minimum
standards for the preparation of a code of practice for permanent and moveable underground
substations in coal mines;

l) documentation that contains a risk assessment that can be done in accordance with the COP
mentioned in (k);

m) the results of any risk assessments recorded in documents that cover

1) the nature of proposed work to be undertaken on energized equipment, and

2) the results of any testing carried out during the assessment and any conditions associated
with the maintenance of energized equipment which the assessment has shown to be
necessary;

n) safe operating procedure (SOP);

o) a mini-risk assessment;

p) task observations.

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4.5 Qualifications and training

4.5.1 The installation, inspection and maintenance of installations shall be carried out only by
competent personnel. Training shall include instruction on the specific explosion-protected
equipment used at the relevant mine. Appropriate refresher courses shall be given to personnel that
perform inspection, maintenance and installations on a regular basis.

4.5.2 Personnel that operate MV switchgear shall be trained for site-specific MV operations, and
shall be appointed in writing.

4.5.3 The responsible personnel for the installation, inspection or maintenance of the equipment
shall

a) be familiar with the requirements of any relevant standard, the recommendations of any relevant
code of practice and any relevant regulation;

b) have access to all information necessary to carry out the assessment;

c) be familiar with the requirements in annexes A and B.

5 Installation
5.1 General

5.1.1 In addition to complying with the requirements of this part of SANS 10086, electrical
installations in hazardous areas shall also comply with the appropriate national electrical standards
and recommendations for installations in non-hazardous areas.

5.1.2 Explosion-protected equipment shall be located or otherwise protected so as to ensure, as

far as is reasonably practicable, that damage to the equipment by external factors such as mobile
machinery does not occur.

5.1.3 Every mine shall draw up and have in force a code of practice for installation of electrical
equipment. Electrical equipment shall be fit for purpose and due consideration shall be taken to
ensure that the following issues have been covered:

a) adequate ventilation for cooling;

b) environmental conditions;

c) adequate space for maintenance and major repairs;

d) proper inspection access;

e) isolation and lockout facilities;

f) electromagnetic interference with control and data equipment;

g) positioning of equipment to prevent dust build-up and contamination;

h) adequate lighting;

i) proper placement of monitoring equipment;

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j) clear and understandable marking of equipment;

k) proper cable support;

l) compliance with good earthing practices;

m) fire fighting equipment;

n) avoidance of mechanical damage; and

o) test certificates and test reports for equipment.

5.1.4 Enclosures with unused openings for cable entries in electrical equipment shall be closed
with blanking elements suitable for the relevant type of protection required and certified as such.

5.2 Electrical protection and control techniques for switchgear and panels

5.2.1 Techniques

Due note should be taken of the electrical protection techniques which are applicable to equipment
that feeds explosion-prevention equipment in mines. The techniques (or components) for electrical
protection on explosion-protected equipment are outlined in 5.2.2 to 5.2.20. Protective devices shall
be set to the correct values, taking into consideration cable current ratings and connected loads.

5.2.2 Fault clearing devices

5.2.2.1 General

Fault clearing devices shall be selected and set by competent persons to provide suitable protection
for the various electrical motors, devices, components and cables within the electrical system. The
correct component ratings, device ratings and cable ratings shall be specified on the manufacturer's
design drawing.

Changes to any of the settings or substitution of any of the components, devices or cables with an
incorrectly rated part might

a) invalidate the relevant component certification or test report (or both),

b) enable equipment surface temperatures to rise above the maximum allowable safe temperature,

c) expose cabling to the risk of fire due to cable damage or faults, and

d) lead to catastrophic equipment damage and short-circuit explosions.

5.2.2.2 Typical fault clearing devices

5.2.2.2.1 Circuit-breakers

The correct fault break rating, continuous current rating and voltage rating shall be selected.

NOTE Fuse elements should always be regarded as live, and special safety precautions should be taken to
isolate fuse elements during the replacement process.

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5.2.2.2.2 High rupturing capacity fuses (HRC fuses)

A HRC fuse is a device that is designed to interrupt a circuit that is subjected to a short-circuit
condition.

Under certain fault conditions the HRC fuse is superior to other older generation interrupting
devices (such as air, oil, vacuum and SF6 circuit-breakers) for the following reasons:

a) a correctly rated fuse has the characteristic of being able to limit the short-circuit currents to a
value that is less than the prospective peak value in the first half-cycle;

b) it is an economical protective device;

c) the HRC fuse can be used in conjunction with other interrupting devices in order to achieve
optimal short-circuit protection systems; and

d) the HRC fuse installation is relatively small for the interrupting capacity of the fuse elements.

NOTE 1 The main disadvantage of a HRC fuse installation is that all fuses that protect a three-phase circuit
should be replaced in the event of one or more fuses blowing. Thermal ageing characteristics need to be taken
into account when fuses are being selected to accommodate starting currents and overloading. Single phasing
effects need to be provided for or prevented.

NOTE 2 Contactors are switching devices and generally have a limited short-circuit clearing capacity. On-load
and off-load isolators are not fault tripping devices.

NOTE 3 Fuse elements should always be regarded as live, and special safety precautions should be taken to
isolate fuse elements before the replacement process.

5.2.3 Overload protection

5.2.3.1 Overload protection is provided to ensure that current-carrying equipment is not overloaded
to an extent that overheating of the equipment occurs.

5.2.3.2 Overload protection is generally provided to ensure that the load rating of cables, motors,
busbars in banks of gate-end boxes and transformers is not exceeded and any equipment not
equipped with dedicated overload protection is not damaged through excess mechanical or
electrical load.

5.2.3.3 Protecting multiple equipment by means of a single overcurrent device is inadequate

overload protection. Such protection is unable to detect an overload on one or more of the items of
equipment. This can lead to serious overheating of the equipment and to the possibility of an
ignition. Overload protection of individual equipment is necessary.

5.2.4 Short-circuit protection

5.2.4.1 A short circuit occurs when the normal or designated path of current flow to the connected
load is diverted to another part of the circuit. This is an abnormal condition where a large amount of
energy is dissipated due to high fault currents.

5.2.4.2 Short-circuit protection, or phase-fault protection, is provided by a suitably rated fault

current interrupting device which will open in the event of a short circuit (fault condition).

5.2.4.3 Users shall be aware that the switchgear in many older generation flameproof gate-end
boxes is inadequate to clear the high currents associated with short circuits. For this equipment, the
manufacturers provide protection which “back trips” a suitably rated remote circuit-breaker in the
feed to the gate-end box. Whenever such a “back tripping” arrangement is provided, it shall always

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be used to prevent potentially serious damage to the components, and possibly the enclosure, of a
flameproof gate-end box.

5.2.4.4 Where possible the short-circuit protective device on the primary side of a transformer shall
be sufficiently sensitive to clear a primary or secondary winding short-circuit fault.

5.2.5 Sensitive earth fault protection (50 Hz)

5.2.5.1 The purpose of sensitive earth fault protection is to disconnect a circuit in the event of an
earth fault.

5.2.5.2 Sensitive earth fault protective devices are utilized in the mining industry to

a) possibly reduce the hazards to personnel associated with earth faults, and

b) protect machinery and equipment by limiting the earth fault energy levels.

NOTE Isolation of a single earth fault prevents the possibility of a short circuit that occurs due to a second
earth fault.

5.2.5.3 The sensitive earth fault relay system monitors the fault current that flows to earth and if it
exceeds a preset limit, the power circuit supply will be tripped (disconnected).

NOTE It is important to note that earth fault protection used in mines is not intended to protect personnel
against direct contact with live parts. This excludes hand-held face drills that have low set earth leakage
protection (see earth leakage protection in SANS 10142-1).

5.2.5.4 Machines used in a hazardous area are required to be supplied from a transformer, which
has a restricted neutral, and by a cable that has individually screened power cores. Sensitive earth
fault protection relies upon the return path to the transformer neutral to be as low a resistance as
possible.

5.2.5.5 Sensitive earth fault testing and reset buttons are contained under covers or are access
controlled. Compliance with the mine-specific code of practice is required for a member of the
personnel to be allowed to control access and reset a fault condition.

5.2.6 Earth fault search and lockout protection

Earth fault search and lockout protection shall comply with BS 7202. Earth fault search and lockout
protection is intended to detect damage or deterioration of the insulation (the insulation resistance
level) on screened flexible cables and equipment, the potential for an earth leakage fault (by the
injection of a low-voltage d.c. along the power conductors) before the equipment is energized. This
protection is used with explosion-protected equipment because even restricted earth fault currents
are capable of igniting an explosive concentration of methane or coal dust.

5.2.7 Continuous earth continuity monitoring (general power distribution systems)

5.2.7.1 The electrical cable armouring or screen (or both) is used for earth continuity purposes. In
addition, a copper conductor might be used as an earth conductor.

5.2.7.2 An earth continuity monitoring system is designed to continuously monitor the resistance of
the earth path between the power source and equipment through the cable earth (armouring, or
dedicated cable earth conductor, or earth screen). A pilot conductor in the cable is required to
enable a control loop to be achieved. The control loop is terminated at the remote end of the cable
by a resistor or a diode module (or both) that provides a monitoring facility for short circuits, open
circuits and high resistance in the pilot conductor and earth loop. An earth continuity monitoring
system, when used as an intrinsically safe circuit, shall comply with SANS 60079-11.

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NOTE 1 The earth continuity monitor injects an intrinsically safe signal through the loop formed by the pilot
conductor, remote module and earth return path. The system monitors the voltage and current that flow in the
loop. The values of the current and the voltage allow the loop resistance value to be calculated. If the
resistance value exceeds the pre-set ohmic limit, the protection operates by disconnection of the power supply.

NOTE 2 Although the supply for earth continuity monitoring is tested and certified as intrinsically safe, earth
continuity monitoring systems are not considered as intrinsically safe when the cable is energized, since
induction from the power conductors in a cable might raise the earth continuity monitoring voltages to non-
intrinsically safe levels. Therefore any remote-switching devices used with earth continuity monitoring should
be certified flameproof.

5.2.8 Pilot protection

5.2.8.1 Pilot protection shall comply with BS 3101 or AS/NZS 2081, and the following functions
shall be performed.

a) Monitor the earth (loop) path continuity; it shall trip the supply in the event of an open circuit,
short circuit or high resistance in the earth loop.

b) Provide remote control of a switching device such as the contactor in a gate-end box, when
required.

c) Trip the supply to the protected cable or equipment in the event of a pilot core to earth fault. For
this protection to operate, the diode in the pilot circuit shall always be installed at the remote end
of the system.

NOTE It is a contravention of safe practice to install the diode at a point other than the remote end of the
system.

d) Trip the supply to the protected cable or equipment in the event of a drop in voltage to levels that
would result in damage to equipment, and prevent the circuit being automatically made live
when the voltage recovers.

e) Where "pilot stop start control", either in local or remote, is used and the supply to the protected
cable or equipment is removed for any reason other than the pilot trip, the pilot circuit shall trip
and require manual restarting.

f) Trip the supply to the protected cable or equipment in the event of a restrained plug and socket
accidentally being opened while live.

WARNING: Users should never make use of this facility by deliberately opening a live coupler.

g) Install a test facility to ensure that correct operation of the relay is performed.

NOTE Although the supply for pilot wire protection is tested and certified as intrinsically safe, a pilot protection
system is not considered as intrinsically safe when the cable is energized, since induction from the power
conductors in a cable might raise the pilot protection voltages to non-intrinsically safe levels. Therefore all
remote-switching devices used with pilot protection systems should be certified flameproof.

5.2.8.2 Auxiliary power outlets on board mobile machines, which might become live, i.e. supplies
for off-board fans, shall be fitted with pilot circuit protective devices to ensure that no power can be
applied to the outlet without the circuit being complete.

NOTE It is strongly recommended that undervoltage trip circuits be used in hazardous areas. Shunt trip circuit
can briefly energize which could result in a person being exposed to a live circuit.

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5.2.9 Neutral earthing resistor (NER)

5.2.9.1 The neutral earthing resistor limits the fault current to a maximum of 2,5 A. Lower values
are preferred, however, to reduce touch potential.

5.2.9.2 The NER shall be segregated from other equipment and wiring.

5.2.9.3 Heat generated by the NER under fault conditions should be taken into account when any
other equipment, which is in the same enclosure or in close proximity, is being selected.

5.2.9.4 The external surface temperature of the NER housing shall be limited to a maximum of
150 °C.

5.2.9.5 The NER shall be continuously rated.

5.2.10 Neutral earthing resistor monitoring (NERM)

5.2.10.1 General

A NERM system shall be provided to trip the supply to a transformer located in a hazardous area,
where in the event of the earth fault limiting resistance, known as an NER, in the transformer
secondary neutral-to-earth connection being faulty. Failure of the resistor or conductor in the
neutral-to-earth circuit will result in a dangerous situation.

5.2.10.2 Neutral earthing resistor monitor

5.2.10.2.1 A fault in the neutral earthing resistor known as the NER shall be detected by a neutral
earthing resistance monitor, i.e. an increase in the value of resistance to more than 1,5 × the
original value.

5.2.10.2.2 Minimum requirements for a NERM shall be to

a) continuously monitor the integrity of the resistor, i.e. with a NERM relay,

b) give tripping indication (this tripping indication shall be maintained under power failure conditions
and there shall be restricted access to the reset function),

c) provide a NERM test facility, and provision shall be made to prevent unauthorized operation,

d) have a separate connection for the NERM relay monitor wire to the neutral bushing of the
transformer.

5.2.11 Neutral earth fault relay

5.2.11.1 A standby earth fault relay shall be configured to detect an earth fault current in the neutral
earthing circuit.

5.2.11.2 Minimum requirements for a earth fault relay shall be to provide

a) earth fault current protection (normally adjustable),

b) time delayed tripping (normally adjustable),

c) tripping indication (this tripping indication shall be maintained under power failure conditions and
there shall be restricted access to the reset function),

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d) an earth fault test facility, and provision shall be made to prevent unauthorized operation,

NOTE If the neutral circuit is an open circuit, the neutral earth fault relay will not function.

5.2.12 Frozen contact protection

Frozen contact protection is used with equipment in hazardous areas in mines, to prevent an
outgoing phase contact or phase contacts from remaining live after the switching device has failed
to disconnect the outgoing supply, for example, by means of back tripping to an upstream point of
supply.

5.2.13 Vacuum contactor protection

5.2.13.1 Vacuum contactor protection is used to prevent accidental electrical shock or the risk of
ignition of an explosive atmosphere or material owing to the exposure of live conductors.

5.2.13.2 Vacuum contactor protection is used where vacuum contactors are utilized to supply
remote electrical equipment using restrained plugs and sockets or bolted couplers (or both) through
a trailing cable in association with a pilot control circuit. In the event of such a failure, a back-tripping
system shall be used to isolate the incoming supply.

5.2.13.3 The inherent design and construction of a vacuum contactor assembly requires vacuum
contactor protection in the case of mechanical failure or vacuum failure, which, in turn, could result
in exposed conductors being live.

5.2.13.4 The contacts within a specific vacuum bottle are normally held closed by the internal
vacuum and are mechanically held apart, only when assembled as part of the contactor until the
contactor is electrically closed. Thus any mechanical failure in the system could cause premature
closing of the contacts.

5.2.13.5 In the case of vacuum loss or mechanical failure, the relatively small gap between the
contacts might cause arcing across the contacts and a voltage to appear on the outgoing terminals.
In most cases the starred impedance used for earth leakage search and lockout system is also
used as the monitor for detection of "through bottle failure".

5.2.14 Phase loss protection

Phase loss protection is used to prevent three-phase motors, in particular, being supplied with a
single-phase supply, which will result in a stationary motor that fails to start and overheats, or an
operating motor that overheats. In the case of motors in hazardous areas, the overheating might
result in the ignition of an explosive concentration of methane or coal dust, or the ignition of a layer
of coal dust on the motor.

5.2.15 Phase rotation protection

Phase rotation protection is used to prevent motors from operating in reverse in the event of phases
being reversed. In both hazardous and non-hazardous areas, reversing of motors might cause
conveyor systems to jam with resultant overheating or ignition (or both) of the conveyor belt and
coal.

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5.2.16 Live line indication

Live line indication is usually provided by means of a group of lights to indicate that equipment in a
panel is live. Failure of these lights should be attended to since such failure can lead to a serious
accident. Live line indication only gives warning and does not cause tripping.

5.2.17 Back tripping

5.2.17.1 Back-tripping functions include

a) tripping of a remote circuit-breaker in the event of a short-circuit fault which cannot be

adequately cleared by the switching equipment in a gate-end box,

b) tripping the supply to an item of equipment or part of equipment to prevent live conductors from
being exposed by the removal of a cover or the opening of a door, and

c) tripping the incoming supply to a transformer in the event of the operation of the NERM
protection.

5.2.17.2 Where back tripping is provided by the manufacturer, it shall be incorporated into the
protection system. Failure to do so could result in potentially lethal conditions.

5.2.18 Co-ordination

5.2.18.1 General

In accordance with SANS 60947-1, the manufacturer shall be required to state the type or the
characteristics of the short-circuit protective device (SCPD) to be used with or within the equipment,
as applicable, and the maximum prospective short-circuit current for which the equipment, including
the SCPD, is suitable, at the operating voltage(s).
NOTE The current should be plotted as abscissa and the time as ordinate, using logarithmic scales. The
current should be plotted as a multiple of the current settings and the time should be plotted, in seconds, on
the standard graph sheet detailed in SANS 60269-1 and SANS 60269-2.

5.2.18.2 Co-ordination types

5.2.18.2.1 General

There are two types of co-ordination defined in SANS 60947-4-1, depending on the attempted level
of operating continuity. Each type defines the limitation of damage that might be done to the
equipment, generally under short-circuit conditions.

5.2.18.2.2 Type 1

Damage to the contactor or thermal overload relay (or both) is accepted provided that

a) there is no risk of danger to the operator, and

b) the damage to the equipment is restricted to the above-mentioned components, i.e. no other
device should have to be replaced.

5.2.18.2.3 Type 2

5.2.18.2.3.1 The only damage allowed is slight welding of the contacts on the contactor; these can
easily be separated by removal of the contactor coil supply or by light pressure from a screwdriver
or other suitable tool.

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5.2.18.2.3.2 Damage to the contactor or thermal overload relay (or both) is accepted provided that

a) protective devices shall remain in working order, and

b) should the contacts be separated by the use of a tool, the manufacturer of the contactor shall
prove that the device is still operational for further service by applying 20 operating cycles at
twice the rated current applicable for AC-3 duty (see 5.2.19.3).

5.2.18.2.3.3 There are three methods of ensuring type 2 co-ordination:

a) by using a suitably rated contactor that is capable of breaking the fault current. This is normally
not a solution, as the fault current would greatly exceed the current-breaking capacity of an
economically viable contactor;

b) a circuit-breaker might be used, provided there is a suitable time discrimination between the
circuit-breaker and the contactor. This is sometimes referred to as "back tripping"; and

c) by using fuses that are designed for the purpose of type 2 co-ordination.

5.2.19 Motors
5.2.19.1 In order to protect cables and motors, switchgear normally has at least the following basic
protection functions:

a) overload protection – related to the motor and the size of the cable;

b) motor control – on or off realized by the contactor;

c) earth fault;

d) short circuit; and

e) isolation.

5.2.19.2 If a circuit-breaker is used to achieve the function mentioned in 5.2.19.1(d) and

5.2.19.1(e), there should be discrimination between the circuit-breaker and the contactor.

5.2.19.3 The commonly used motor utilization categories in mining applications are for alternating
current applications and are the following (from SANS 60947-4-1):

a) AC-1: Non-inductive loads or slightly inductive loads, the power factor of which is at least equal
to 0,95, for example heating systems;

b) AC-2: Starting, plugging and inching of slip-ring motors, for example overhead cranes;

c) AC-3: Squirrel-cage motors with breaking load under normal running operations, for example,
conveyor belts, compressors and pumps;

d) AC-4: Plugging and inching of squirrel-cage motors, for example hoists.

5.2.20 Equipment circuit identifications

The purpose of this requirement is to ensure that equipment can be correctly isolated whenever
work is done. This can be achieved in one of the ways given in (a) to (c).

a) The equipment can be fitted with a permanent label that indicates the source of supply.

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b) The equipment can be fitted with a tag number or a cable can be fitted with a cable number
adjacent to the equipment. The source of supply can be determined from a drawing or schedule
by reference to the tag number or cable number.

c) The item can be clearly and unambiguously shown on a drawing in which the source of supply is
either identified directly or indirectly through a schedule. For safety reasons, it shall be confirmed
at the initial inspection that the information for all equipment is correct. The availability of the
necessary information for all equipment shall be checked at the periodic inspection. A detailed
inspection, to check that the information is correct, shall be done when the circuit is
disconnected to do other detailed inspections.

6 Inspection
6.1 General
6.1.1 Every mine shall have in force a mine-specific scheme for the systematic inspection and
functional testing of explosion-protected equipment to ensure that it is installed and maintained in
safe working order. (See annex C for the main parameters that affect the frequency of inspections.)

6.1.2 A mine shall have a code of practice, procedures and standards in place that will cover the
selection, purchase, repair, modification, inspection, maintenance and record keeping of Ex
equipment. The typical content of such a code of practice is given in annex D.

6.2 Types of inspection

There are two types of inspection as given in (a) and (b).

a) Initial inspection. Before any new, repaired, refurbished or modified explosion-protected

equipment is brought into service, it shall be given an initial inspection to ensure that it is
suitable for use in a hazardous area. An initial inspection is done to check that the selected type
of protection and its installation is appropriate.

b) Periodic inspection. An inspection of all equipment is carried out on a regular basis (for
example, once a shift, once a day, once a month). The frequency of periodic inspections shall be
determined by the mine authorities, taking into account the type of equipment, manufacturer's
recommendations, if any, the factors governing its deterioration and the results of any previous
inspections. (See annex E for a typical inspection procedure.)

6.3 Grades of inspection

6.3.1 The nature of inspection can be one of the following (see definitions):

a) visual,

b) close, or

c) detailed.

6.3.2 Tables F.1, F.2 and F.3 (see annex F) detail the specific checks required for these three
grades of inspection. Visual and close inspections can be performed without opening the equipment
and might therefore be executed with the equipment energized. Detailed inspections require the
equipment to be opened and will require the equipment to be isolated, locked-out and de-energized.

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6.3.3 The methods used and the grade of the inspections and tests shall be detailed in a mine-
specific scheme. Arrangements shall be made for recording the results of all such inspections and
tests.

6.3.4 An initial inspection shall be a detailed one as referred to in tables F.1, F.2 and F.3, as
appropriate. The results of initial inspections shall be recorded.

6.3.5 Subsequent to an initial inspection, periodic inspections shall be carried out to ensure that
the installation is being maintained in a serviceable condition for continued safe use in the
hazardous area.

6.3.6 Periodic inspections can be "visual" or "detailed" or "close" as referred to in tables F.1, F.2
and F.3, as appropriate. A visual or close periodic inspection might indicate the need for a detailed
inspection.

6.3.7 Inspections are done as follows:

a) a visual inspection takes place at the start of every shift;

b) a close inspection takes place once a day or once in seven days; and

c) a detailed inspection takes place once in 30 days or once in 90 days.

6.4 Moveable equipment

Moveable electrical equipment (hand-held, portable and transportable) is particularly prone to
damage or misuse and therefore the frequency of detailed inspections might need to be increased.
Moveable electrical equipment shall be submitted to a detailed inspection as defined in the mine-
specific requirements. In addition, the equipment shall, before use, be visually checked by the user,
to ensure that the equipment is not obviously damaged. The results of detailed inspections shall be
recorded.

6.5 Conditions of use

6.5.1 Special conditions for safe use apply to any type of certified explosion-protected equipment
where the certificate number has a suffix "X". The certification documents shall be studied to
ascertain the conditions of use.

6.5.2 The user and installer shall consider any special conditions that might apply to the safe use
of the equipment, as specified in the certification documents. An example of such a condition is a
rotating machine that is cooled by a medium other than air, such as forced water. Protective devices
shall be installed on the machine to prevent overheating owing to the loss of the coolant.

6.5.3 Users of explosion-protected equipment shall report any physical damage to explosion-
protected equipment to a competent person as soon as such damage occurs or is noted. The
competent person shall examine the equipment and shall have the equipment removed from
service and repaired if the equipment is deemed to be unsafe for use.

6.6 Internal faults in flameproof enclosures

6.6.1 Users of flameproof electrical equipment shall recognize that flameproof enclosures are
generally unable to withstand severe internal electrical faults without serious damage to the
enclosure.

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6.6.2 To prevent internal electrical faults, the requirements in (a) to (d) shall be adhered to:

a) All components installed or provided by the manufacturer to prevent short circuits such as flash
barriers, insulating components, and grommets, shall not be removed, or shall be replaced if
removed for maintenance or other purposes.

b) All internal cables, conductors and other components used with medium-voltage supplies shall
be protected against corona and shall be periodically examined to ensure that corona has not
caused deterioration of the insulation of such cables, conductors or components.

c) Internal connections used for power circuits shall be torqued, since a loose connection might
result in a hot or arcing connection and lead to ionization within the enclosure resulting in a
phase or earth fault. A hot connection leads to degradation of conductor insulation.

d) Enclosures shall be examined periodically in order to prevent accumulations of coal dust or

moisture (or both) that might result in a phase or earth fault condition (short circuit).

6.6.3 If an internal short circuit has occurred within a flameproof enclosure, the enclosure shall be
carefully examined for obvious damage to ensure that the enclosure still complies with the design
requirements. Should obvious visual damage such as any distortion of the enclosure or fixing
components such as bolts have occurred, or should other damage be suspected, the enclosure
shall be returned to the manufacturer or repairer for repair and testing. If there is any doubt
regarding the integrity of the equipment, the OEM should be consulted.

6.7 Intrinsically safe systems

Users are reminded that a circuit that contains intrinsically safe equipment is considered as a
system and requires certification by an accredited test laboratory. Any unauthorized additions,
repairs or modifications to the system by the user will negate the certification of the system and can
render the system unsafe for use in a hazardous area.

6.8 Earth leakage testing

6.8.1 Since the current levels in a phase-to-earth fault will always be capable of igniting an
explosive concentration of methane or coal dust, the function and correct operation of the earth
leakage protection is of the utmost importance, and shall be maintained in working order at all
times.

6.8.2 In order to test the operation of an earth leakage circuit, each manufacturer's operational
manual shall be consulted and a specific procedure drawn up, with due reference to frequency of
tests and recording of results.

6.8.3 Only authorized personnel shall carry out testing of the operation of earth leakage protection.

6.8.4 Equipment that fails to trip under test conditions shall not be used until it has been repaired
and tested and found to be in order.

6.8.5 Where there are no internal test circuits fitted to the equipment, certified earth leakage test
units shall be used in accordance with the manufacturer's operating procedures.

6.8.6 Where three-phase power transformers are used on-board mobile machines to supply
variable speed drives and other power circuits, the secondary winding of the on-board transformer
and the circuits supplied should be protected by a suitable earth leakage protective device. A test
and reset facility shall be provided, and shall be checked as part of the pre-shift start-up

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procedures. An earth fault limiting impedance should be connected to the neutral of the secondary
winding of the transformer.

NOTE Consideration should be given to the effect of d.c. and inverter system harmonics on the operation of
earth leakage relays.

6.8.7 Results of each test shall be recorded.

6.8.8 The frequency of these tests shall be in accordance with the mine’s maintenance scheme in
consultation with the manufacturer's recommendations.

6.9 Coal dust on explosion-protected equipment

Layers of coal dust on any electrical equipment which generates heat during operation might
interfere with the cooling of such equipment and result in overheating. Apart from the danger that
overheating poses to electrical equipment, in hazardous areas the layers of coal dust might ignite or
start to smoulder. Every effort shall be made by replacing or regular cleaning (or both) of equipment
to minimize the accumulation of coal dust.

NOTE Overload protection is unable to detect overheating caused by any material or condition which
interferes with the normal cooling of the equipment.

In addition, coal dust accumulations on insulators might result in a short circuit or earth fault which
might, in turn, ignite the coal dust or flammable gas.

7 Maintenance
7.1 General
7.1.1 Every mine shall have in force a code of practice on the maintenance of electrical equipment.
Only authorized maintenance personnel shall carry out maintenance on equipment. Due to
equipment diversity, special attention and training shall be required to carry out any maintenance.

7.1.2 The following issues shall be taken into account when maintenance is conducted:
a) proper isolation and lock-out procedures;

b) proper pre-maintenance procedures shall be in place while maintenance is being conducted in

hazardous areas;

c) proper protective equipment which shall be used during maintenance;

d) correct test equipment and, when required, certified test equipment;

e) the maintenance area shall be inspected and made safe for maintenance;

f) modification and repairs shall only be carried out by approved repairers;

g) equipment integrity shall not be affected while maintenance is being carried out;

h) a strategic maintenance plan shall be in place;

i) tests done during maintenance shall be properly defined and results recorded;

j) replacement equipment shall be selected not to invalidate original certified designs;

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k) risk assessments (see annex G) and task observations (see annex H);

l) environmental conditions might have a destructive effect on equipment and shall be addressed
during maintenance;

m) earth continuity tests shall be recorded; and

n) all energy storing devices shall be taken into consideration, i.e. electrical charged circuits, kinetic
energy spring storage, potential energy of falling objects and chemical energy heat sources.

7.2 Test equipment

Any electrical test instrument used to test a circuit or system shall, where practicable, be of robust
construction and design for use in an underground mining environment. Test instruments for use in
hazardous areas shall be approved by a certified test laboratory for use in such areas.

7.3 Flameproof joints

7.3.1 When flameproof joints are being reassembled, all joints shall be thoroughly cleaned and, if
not permanently protected with an anti-corrosive layer, lightly smeared with a suitable grease as
recommended by the OEM, to prevent corrosion and to assist weatherproofing. Blind bolt-holes
shall be kept clear of grease. Only non-metallic scrapers and non-corrosive cleaning fluids shall be
used to clean flanges.

7.3.2 It is normally considered not necessary to check the diametrical clearances of spigot, shaft,
spindle and threaded joints, unless there is evidence of wear, distortion, corrosion or other damage,
in which case reference shall be made to the manufacturer's documents. Joints, which are normally
not capable of being dismantled, need not be subjected to the inspection checks listed in table F.1.

7.4 Fasteners and tools

Fasteners, upon which the type of protection depends, shall only be replaced with identical parts in
accordance with the manufacturer's design.

Where special bolts and other fasteners or special tools are required, these items shall be made
available to competent personnel only.

7.5 Use of solvents for cleaning

Unless authorized by the manufacturer, solvents shall not be used to clean windows or non-metallic
materials. The internal electrical components may be cleaned with a recommended solvent. The
use of non-recommended solvents might soften seals or cause window material to deteriorate. In
addition, solvent fumes (volatile flammable liquids) within an enclosure might result in an explosive
mixture for which the equipment is not designed.

7.6 Modifications and repairs

7.6.1 The general condition of all equipment shall be noted periodically and appropriate remedial
measures shall be taken where necessary. Care shall be taken, however, to maintain the integrity of
the type of protection provided for the equipment; this might require consultation with the
manufacturer. Replacement parts shall be in accordance with the manufacturer's recommendations.

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7.6.2 Modifications to equipment that might affect explosion protection characteristics of the
equipment shall not be carried out without consulting a certified test laboratory. The alteration might
adversely affect the safety of the equipment as stated in the safety documentation.

7.6.3 Modifications to equipment that might affect an electrical characteristic of the equipment shall
not be carried out without consulting the OEM or a certified test laboratory.

NOTE See SANS 10108 and ARP 0108.

7.7 Isolation of circuits other than intrinsically safe circuits

7.7.1 Electrical equipment that contains live parts which are not intrinsically safe and is located in a
hazardous area shall not be opened without isolating all incoming and, where necessary, outgoing
connections, including the neutral conductor. Isolation in this context means withdrawal of fuses and
links or the locking off of an isolator or disconnector. The enclosure shall not be opened until
sufficient time has been allowed to permit any surface temperature of internal components to drop
or stored electrical energy to decay to a level below which it is incapable of causing an ignition.

7.7.2 Legislation and regulations (see foreword) permit work to be carried out on explosion-
protected equipment under special conditions of flammable gas surveillance. The work might then
be carried out subject to the precautions that would be applied in a non-hazardous area.

7.8 Light alloys

7.8.1 SANS 10012 gives a full description of light alloys and the dangers of using light alloys in
hazardous areas.

7.8.2 Any light alloy such as aluminium, magnesium, titanium or alloys that contain these metals
can result in potentially dangerous conditions in hazardous areas, and shall not be used unless a
certificate issued by a certified test laboratory indicates them to be safe for use.

7.8.3 Light alloys cannot totally be eliminated from hazardous areas, but where alternative
equipment or a component is available, light alloys shall not be used. Equipment or components
which are made of light alloys, such as diesel engine fuel pumps, are relatively safe when fitted to
machines. However, should such components be replaced, they shall not be discarded
underground but shall rather be taken to the surface and disposed of.

7.8.4 The use of light alloy equipment in non-hazardous areas on mines shall be strictly controlled,
since mobile machines might make contact with the equipment and can then transfer potentially
dangerous smears of light alloy into hazardous areas.

7.8.5 The practice of using aluminium-based paint on conveyors and other steel structures shall
not be permitted anywhere in an underground coal mine.

7.9 Electromagnetic radiation, electromagnetic compatibility (EMC),

electromagnetic interference (EMI)

7.9.1 Electromagnetic radiation has two means of propagation:

a) through an electric field, the strength of which is directly related to the magnitude of the supply
voltage; and

b) through a magnetic field directly proportional to the magnitude of current within a given conductor
or device.

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7.9.2 Electromagnetic radiation can have an effect on the functionality of equipment and on safety
aspects of certain circuits.

7.9.3 Light current devices or voltage sensitive components might be rendered non-operational or
even be destroyed should the electromagnetic field be significantly large.

7.9.4 The currents and voltages of intrinsically safe circuits are inherently limited to levels that
comply with specific criteria laid down in standards. These levels might be exceeded when in the
vicinity of electromagnetic radiation, thereby rendering them unsafe.

7.9.5 In the design of equipment, suppliers shall ensure that the layout of cables and components
do not have a significant negative effect in terms of EMC and EMI on circuits or components. This is
generally accomplished by segregation or by means of suitable shielding.

7.9.6 During repairs or maintenance, the component and cable layout shall remain the same as
when the equipment was supplied by the manufacturer.

7.10 Environmental conditions

7.10.1 Electrical equipment in a hazardous area might be adversely affected by the environmental
conditions in which it is used. Some of the key elements to consider are corrosion, ambient
temperature, ingress of water, accumulation of coal dust, stone dust or sand, mechanical effects
and chemical attack.

The corrosion of metal or the influence of chemicals (particularly solvents) on plastics or elastomeric
components might affect the type and degree of protection of the equipment. Should the enclosure
or a component become severely corroded, the relevant part shall be replaced. Metallic enclosures
of equipment shall, where necessary, be treated with an appropriate protective coating as a
precaution against corrosion, the frequency and nature of such treatment being determined by
environmental conditions.

7.10.2 If the marking of the explosion-protected equipment does not indicate a range of ambient
temperatures, it shall only be used within the range -20 °C to +40 °C. If a range is indicated, the
equipment shall only be used within the indicated range.

7.10.3 All parts of installations shall be kept clean and free from accumulation of dust and harmful
substances of such a nature that they could cause excessive rise in temperature, and act as a
source of fuel.

NOTE Multi-layers of paint could result in excessive temperature rise in equipment or on the surface of the
equipment.

7.10.4 Care shall be taken to ensure that the ingress protection of equipment is maintained.
Damaged gaskets shall be replaced.

7.10.5 Anti-condensation devices such as breathing, draining or heating elements shall be

checked to ensure correct operation.

7.10.6 If the equipment is subject to vibration, special care shall be taken to ensure that bolts and
cable entries remain tight.

7.10.7 Care shall be taken to avoid the generation of static electricity during the cleaning of
non-conductive electrical equipment.

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8 Specific types of protection

NOTE The most common explosion protection techniques used in mines are Ex i and Ex d and, less often,
Ex e.

8.1 Intrinsically safe Ex i systems

8.1.1 Simple equipment
8.1.1.1 Simple equipment usually consists of electrical equipment that act as sources of generated
energy (for example, thermocouples and photocells), which do not generate more than 1,5 V,
100 mA and 25 mW.

8.1.1.2 Simple equipment shall comply with intrinsic safety requirements, but need not be
separately certified and Ex marking need not be applied to these units. Marking to aid inspection
and maintenance work is recommended. More detailed information on simple equipment is given in
SANS 60079-11.

8.1.1.3 The use of simple equipment shall take into consideration

a) its use in intrinsically safe systems should form part of system approval,

b) the use of simple equipment with intrinsically safe equipment should be approved,

c) temperature classification,

d) insulation from earth should be verified, as is normally required for intrinsically safe circuits,

e) specific requirements for terminals or connection facilities, and

f) the composition of material or light metal alloys used in the construction of enclosures shall
comply with the requirements of SANS 10012 and SANS 60079-0.

8.1.2 Associated equipment

8.1.2.1 Associated equipment is usually

a) electrical equipment with an intrinsically safe output (in some instances an input) protected by
another type of protection listed in SANS 60079-0 (for example, an intrinsically safe power
supply might be housed inside a flameproof enclosure), or

b) electrical equipment with an intrinsically safe output or input, positioned in a safe area.

8.1.2.2 The rated maximum voltage (Um) to the associated equipment shall not be exceeded. The
circuit shall be protected to a maximum short-circuit current not exceeding 1 500 A or a value stated
for the associated equipment.

8.1.3 Intrinsically safe system

The words “intrinsically safe” imply that a certificate of intrinsic safety has been granted by a
certified test laboratory either for the intrinsic safe system as a whole or for the individual items of
equipment. In the latter case, the certificate for the principal item of equipment would define the type
of, or limiting parameters of, the power supply to be used. Information on the limiting parameters of
the connecting cables, on the method of connection, and on any connections to other equipment
that are permitted, may also be obtained from the certificate.

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In both cases, the intrinsically safe system is properly defined, with the main difference being that a
single certificate might be issued for the items of equipment when they are submitted for approval
as a system whereas the second approach normally involves equipment that carries separate
certificate numbers and a system approval after the specific configuration of equipment has been
certified.

8.1.4 Categories of intrinsically safe systems

8.1.4.1 Two categories of intrinsically safe systems are defined according to the number of faults
that can be applied after which the system will still remain intrinsically safe.

8.1.4.2 A category "ia" system remains intrinsically safe under normal conditions with up to two
countable faults in the system, while a category "ib" system remains intrinsically safe under normal
conditions with one countable fault. The types of fault applied are determined by SANS 60079-11
and the test laboratory. The number of faults applied depends on the category of the system.

NOTE When certified equipment is used together in a system, the use of the safety parameters already
considers internal fault conditions in the equipment. During system certification, faults which could not be
considered during individual certification, for example in the interconnecting cables, might be considered.

8.1.4.3 Intrinsically safe equipment might have a category "ia" when utilized as in the certificate but
might not retain this category or even its intrinsic safety when connected to other intrinsically safe
equipment when this configuration is not approved as a system. An example of this might include
an item of intrinsically safe "ia" equipment connected to a category "ib" power supply, which will
render the entire system category "ib" after system certification.

8.1.5 Certification of intrinsically safe systems

8.1.5.1 General

Intrinsically safe system approvals might be done on a generic basis. This means that the worst-
case scenarios, future development, different types of equipment that might be used in the system,
etc. might be considered on one generic or representative drawing. As long as the generic drawing
and system certification or approval is complied with, different configurations of equipment can be
used and further certification is not required.

However, any changes, for example, different types of equipment, different cable specifications,
equipment certified by other manufacturers, and changes in earthing requirements not included on
such a generic type of approval, shall be incorporated into the system certification, and the
certification shall be updated.

8.1.5.2 Basic approaches

8.1.5.2.1 The two basic approaches to system approval in intrinsic safety are given in (a) and (b).

a) The certification of the system of interconnecting units by the manufacturer of the system. This
approach does not generally mean that no other intrinsically safe equipment may be
interconnected to the system, except if allowed by the manufacturer and if the system is certified
to include the additional equipment.

NOTE The involvement of the manufacturer might be required to obtain the design documentation of the
system, for the purpose of applying the fault conditions and assessing the system’s intrinsically safe
integrity when additional equipment is interconnected.

b) The use of individually certified equipment for interconnection into a system. Certification of the
system is achieved by the use of safety parameters assigned to the individual units. The

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parameters and construction of the cable play as an important role in the system as do the
individually certified units. The use of the safety parameters is guided by the following rules:

Uo < Ui

Io < Ii

Po < Pi

Co > Ci + Ccable

Lo > Li + Lcable

8.1.5.2.2 The Um of the power supply or interface device (for example a barrier) shall not be
exceeded.

NOTE See 3.1.39 to 3.1.50 for definitions.

8.1.5.2.3 In 8.1.5.2.1(b) above, documentation that contains at least the required documentation
and indications in (a) to (i) below shall be submitted to a certified test laboratory for approval or
certification of the system.

a) A system drawing, the relevant certification documentation and the cable specifications.

b) Distinction between hazardous and safe areas (for example, the inside of a flameproof
enclosure) shall be clearly marked on the drawing, so as to indicate the area of all the
equipment in the relevant areas.

c) A description of the hazardous area with regard to the degree of the hazard (zone), flammable
substance (type of gas or dust (or both)), temperature classification (of the gas) and the ambient
temperature range.

NOTE Intrinsically safe equipment is generally approved for an ambient temperature range of -20 °C to
40 °C, unless otherwise stated. The effect of installation inside a flameproof enclosure, within a hot
process, etc., should be considered as part of the system certification.

d) All interconnecting cables and conductors shall be shown.

e) Compliance with the safety parameter rules in 8.1.5.2.1(b) should be indicated on the system
drawing.

f) The intrinsically safe equipment shall be listed by means of a description, the manufacturer, the
type or model, the certificate number, the test laboratory and the explosion protection rating.

g) Where equipment is simple equipment, a statement to this effect should be made.

h) Details on all interconnecting cables shall be documented with regard to type, armouring,
screening, insulation test voltage, capacitance, inductance (or L/R (or both) parameters where
applicable) and the maximum intended length used. A manufacturer’s data sheet which
indicates the construction of the cables should be submitted.

i) Earthing requirements shall be indicated by referencing the earthing of the armouring, screens,
instrument housings, junction boxes and unused cable cores.

8.1.5.2.4 Where earth connections are necessary to preserve the integrity of intrinsically safe
circuits such as in the case of a diode safety barrier, reference shall be made to the design of the

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earth connection which will ensure that the impedance from the point of connection to the main
power system earthing point is less than 1 Ω. This earth is normally known as a high integrity or
high quality earth.

8.1.5.2.5 The influence of more than one power supply or interface device or hazardous area
equipment connected into one system should be carefully considered. In general, more than one
power supply cannot be connected in series or in parallel in the same circuit. Feedback currents
and voltages into different associated equipment should be taken into account, and also
combinations of currents and voltages in a system. A specific example can be when currents from
different power supplies or interface devices might accumulate in a common return conductor inside
the hazardous area. Therefore, different intrinsically safe loops will have their own feedback or
return conductor inside the hazardous area.

8.1.6 Connection facilities for intrinsically safe circuits

8.1.6.1 Contact between intrinsically safe and non-intrinsically safe circuits or conductors might be
prevented by making the connections in different compartments, by physical separation, etc. as
described in SANS 60079-11. The most common means is physical separation of 50 mm between
non-intrinsically safe circuits and intrinsically safe circuits while still taking into account the effect of
wires that might become dislodged.

8.1.6.2 Placement of, and connection facilities for, intrinsically safe circuits should be taken into
account when the intrinsically safe system is being installed (for example in a flameproof enclosure)
and should form part of the system approval.

8.1.7 Insulation of intrinsically safe circuits

8.1.7.1 Generally intrinsically safe circuits are insulated to at least 500 V from earth (see NOTE),
except for a single connection to earth in some instances, and to 1 500 V from non-intrinsically safe
circuits. If equipment does not comply with this requirement, it will be indicated in the special
conditions of use of the equipment and this should then be taken into account in the design of the
system and during the system certification that incorporates such equipment.

NOTE If the equipment does not comply with 8.1.7.1, it is deemed to be earthed.

8.1.7.2 Should two different intrinsically safe circuits be interconnected, it normally leads to an
unsafe condition. Therefore, a 500 V insulation requirement exists between different intrinsically
safe circuits. This includes circuits in multi-core cables.

This requirement shall be taken into account when simple equipment is constructed or used.

8.1.8 Cables used in intrinsically safe systems

8.1.8.1 Only insulated cables with conductor-earth, conductor-screen and screen-earth insulation
ratings of at least 500 V a.c. shall be used.

8.1.8.2 The ends of multi-stranded conductors shall be protected against the spreading of strands
(for example by the use of ferrules). Individual strands of conductors shall have a diameter of at
least 0,1 mm.

8.1.8.3 Additional requirements for multi-core cables are given in (a) and (b).

a) The radial thickness of the insulation shall be appropriate for the diameter of the cable and the
insulation type. For polyethylene, this is at least 0,2 mm.

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b) A 1 000 V insulation test shall be carried out between two bundles, where each bundle
comprises one half of the cable cores joined together. This test is not applicable to multi-core
cables with conducting screens for individual circuits.

8.1.8.4 Intrinsically safe cables shall be either separated from all non-intrinsically safe cables, or so
placed that they are protected against possible mechanical damage, or the intrinsically safe or non-
intrinsically safe cables shall be armoured, metal sheathed or screened.

8.1.8.5 Conductors for intrinsically safe circuits and non-intrinsically safe circuits shall not be run in
the same cable.

8.1.8.6 If metal sheaths or screens are not used for the intrinsically safe or the non-intrinsically safe
cables routed or bundled together (for example, in a duct or on a machine), the intrinsically safe and
non-intrinsically safe cables shall be separated by means of an intermediate layer of insulation
material or an earthed metal partition. This is also applicable to conductors wired inside enclosures
(for example flameproof enclosures).

8.1.9 Marking of intrinsically safe circuits

Except for the applicable Ex marking on the individual units, the marking and certificate number, as
required for the system approval, should be applied on the principal equipment. This shall be
applied to the associated equipment or the enclosure that contains the associated equipment.

The marking of the individual circuits should be taken into account for maintenance and inspection
purposes.

If colour coding is used, cables for intrinsically safe circuits should be light blue. Other ways of
ensuring that conductors inside panels etc. can be identified include labelling, harnessing
intrinsically safe conductors together, arrangement and separation.

8.1.10 Earthing of intrinsically safe systems

8.1.10.1 Intrinsically safe systems are earthed at one point only to the equipotential bonding
system or high integrity earth (for example barriers), or totally isolated from earth (for example
isolators).

8.1.10.2 Galvanic isolated sub-circuits can be separately earthed, each at one point only. Ideally, a
single point is preferable.

8.1.10.3 Where connection to earth through a resistance of 0,2 MΩ to 1 MΩ is used to prevent

static build up in floating systems, this shall not be deemed to be earthing.

8.1.10.4 Where the earthing of the system is important to maintain intrinsic safety (for example a
barrier device), this might be done in one of the following ways.

a) Secure connection (of less than 1 Ω impedance) through the shortest practical route to the equi-
potential bonded system.

b) Install a high integrity earthing point to achieve impedance of less than 1 Ω to the power system
earthing point. Two separate insulated conductors, each rated to carry the fault current (but at
least 1,5 mm2 copper each) might achieve this high integrity earthing point. If one insulated
conductor is used, it shall be rated to carry the fault current, but be at least 4 mm2 copper.

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8.1.11 Earthing of screens

8.1.11.1 Fault currents should be prevented from occurring in the screen of the cable.

8.1.11.2 Screens shall therefore be connected only at one point in the safe area (for example
inside the flameproof box), to the high integrity earth or the equipotential bonding system
(whichever is applicable). In hazardous areas the cable screen is folded back at the point of
connection to the intrinsically safe equipment or simple equipment to maintain the 500 V insulation
requirement. The screen shall be connected through junction boxes (or similar), taking into account
the separation requirements, especially from non-intrinsically safe terminations.

8.1.11.3 If, for functional reasons (for example inductive interference) the screen shall be
connected at other points, additional information should be obtained, for example the integrity of the
equipotential bonding system might be considered for multiple connections. Multiple earthing
through small capacitors might be taken into account (for example 1 nF, 1 500 V), but the total
capacitance should not exceed 10 nF, or as determined during system certification.

8.1.12 Cable armour bonding

Cable armour should form part of the equipotential bonding system and therefore should maintain
the 500 V insulation requirement to the screen and conductors.

Cable armour should maintain the electrical continuity throughout the run of the cable and should be
connected to junction boxes and at each end of the cable run.

Where bonding of the armour at a cable entry point is not practical, or design requirements make
this not possible, care shall be taken to avoid any potential difference that might give rise to an
incendive spark. Further information should be obtained before the armour is bonded including
whether at least one point needs to be connected to the equipotential bonding system, and in which
area or position the isolation of the armour should take place.

8.2 Flameproof protection Ex d

8.2.1 Flameproofing is one of several techniques used to design equipment for use in hazardous
areas.

8.2.2 All flameproof equipment shall have an enclosure with the following characteristics:

a) the enclosure will be strong enough to withstand an internal gas explosion without sustaining
permanent mechanical damage;

b) the enclosure will have well-defined flameproof paths with dimensions that are specific for the
gas where the equipment will be used; and

c) the external surface temperature of the equipment will be below the ignition temperature of the
gas or dust where the equipment will be used.

8.2.3 The characteristics in 8.2.2(a) to 8.2.2(c) above imply that flameproof equipment is designed
for a specific gas group (for example, I or IIA or IIB or IIC) and for a specific temperature class (for
example, 150 °C for coal mining use and T1 to T6 for other applications). The marking that reflects
these details shall be taken into account when the equipment is installed.

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8.3 Increased safety Ex e

8.3.1 Increased safety equipment is designed to prevent the occurrence of any arcing, sparking or
excessive temperatures by means of the application of additional measures to the constructional
requirements and materials for the type of equipment.

8.3.2 Unlike flameproof equipment, every component in the increased safety equipment is of
importance for this type of protection and is usually separately approved or certified (for example,
the lamp holder and ballast in a luminaire or the terminal block and the enclosure for a junction
box). Therefore, components shall not be exchanged for any other components that do not form
part of the original certification of the equipment.

8.3.3 Increased safety enclosures are impact tested and have a minimum protection requirement
of IP54.

8.4 Double protected

The term "double protected" refers to the use of two explosion-protected techniques to protect the
equipment, for example, intrinsically safe equipment housed in a flameproof enclosure (thus double
protected).

9 Specific equipment
9.1 Flameproof transformers

9.1.1 General

9.1.1.1 Transformers and associated switchgear shall be referred to as the “transformer assembly”.

9.1.1.2 Each mine shall have a code of practice for the following:

a) the installation of transformer assemblies;

b) scheduled inspections, which shall be carried out regularly;

c) scheduled maintenance and overhaul programmes, which shall be carried out periodically;

d) operating procedures;

e) risk analysis; and

f) task observations.

9.1.2 Installation

9.1.2.1 General

Due to the arduous operating conditions experienced in a mine, equipment shall be suitable for the
specific application it will be exposed to.

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9.1.2.2 Transformer core heat dissipation

To avoid possible de-rating of design specifications adequate heat dissipation shall be allowed.
Adequate space shall be allowed around the transformer for this purpose. Materials of at least
class H (180 °C) with no paper content should be used for winding insulation. ANAN (air natural air
natural) is recommended for cooling.

9.1.2.3 Transformer core winding

The transformer core winding shall be inspected to ensure bracing and securing of the transformer
core is in place to withstand rigorous conditions and forces which are encountered during
transportation.

9.1.2.4 Tap change links

The tap change inspection cover shall be suitably positioned to ensure ease of access. Connection
drawings of the link positions shall be clearly displayed. Clearances between tap positions and
between the link board and earth shall be adequate.

9.1.2.5 Earth core straps

Earth core straps shall be checked to ensure bond to earth.

9.1.2.6 Connections, bushings, MV switchgear and protection equipment

These shall be rated to withstand full calculated fault conditions and voltage rating.

9.1.2.7 Cable connections or terminations

All MV and LV cable couplings, connections and terminations shall be properly secured, and the
earth continuity maintained with the transformer enclosure.

9.1.2.8 Drawings

Electrical and mechanical layout drawings for the transformer assembly shall be available to allow
for easy identification of components and their connection detail.

9.1.2.9 Approval certification

Ensure that all approval certificates and test reports are available and filed, and that the correct
explosion protected approval has been given for the hazardous area in which the equipment is to be
used.

9.1.2.10 Internal components

Once the transformer assembly has been positioned, all panel doors and inspection covers shall be
opened to ensure that internal components, cables and connections are in place, secure and free
from damage.

9.1.2.11 Busbar connections

All busbar and cable box connections shall be secure and tight.

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9.1.2.12 Protection settings

Protection settings shall be correctly configured and set for the specific installation.

9.1.2.13 Insulation tests

Before energization, the following insulation tests shall be conducted:

a) Test the transformer windings, MV to earth, LV to earth (disconnect neutral earth connection to
perform this test) and between the MV and LV windings. (Ensure the neutral earth connection is
re-secured after the insulation tests have been performed.)

b) Test the incoming MV phase leads, between phases and each phase to earth, and the outgoing
LV phase leads, between phases and each phase to earth. (Ensure that any electronic
instrumentation is disconnected to prevent inadvertent damage. Refer to manufacturer’s
instructions and recommendations.)

NOTE Insulation testing should be carried out with an approved insulation tester and testing should be done
as given in mine-specific standards.

9.1.2.14 Critical safety inspections before energization

9.1.2.14.1 The following critical safety inspections in (a) to (o) shall be carried out before
energization of the transformer assembly.

a) Ensure that the transformer assembly is located in a clean, dry area which is clear of moving
traffic and where the roof and sidewalls are in good condition. The area should be such that the
accumulation of dust or water is minimized.

b) Ensure that adequate space is allowed around the transformer assembly to provide the following:

1) unobstructed ventilation around the transformer assembly;

2) easy installation and removal of incoming and outgoing cables;

3) uninhibited access to the assembly and, in particular, to operating handles, push buttons,
emergency stops, inspection covers, access covers and doors; and

4) free visual access to inspection windows, indication lamps and transformer assembly
labelling.

c) Confirm the integrity of the neutral earth resistor circuit.

d) Confirm the integrity of all back tripping circuits, i.e. the door, cover, short-circuit back tripping
provisions and electrical interlocking.

e) Ensure that all incoming and outgoing adaptors and sockets are clean, free from damage and
secure.

f) Ensure that any drain or blanking plugs fitted are in place and secure.

g) Ensure that all panel doors, inspection and access covers are in place and correctly secured by
the correct specified bolts, which are of a proper and uniform size.

h) Ensure that any instrument glasses and inspection windows are intact.

i) Ensure that all covers over set or reset buttons are fitted and secure.

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j) Measure the flameproof gaps to ensure compliance with SANS 60079-1.

k) Ensure that earth bonding of equipment complies with specific mine requirements.

l) Ensure that the correct type of fire fighting and statutory notices (see foreword) are available,
legible and in position.

m) Ensure that the certification labels are legible and in place and that the correct explosion-
protected product certification mark is displayed for the hazardous area in which the equipment is
to be used.

n) Carry out any other checks or tests advised by the equipment manufacturer or specific mine
standards.

o) Ensure that the correct electrical protection settings are in place.

9.1.2.14.2 Once the inspections in 9.1.2.14.1(a) to 9.1.2.14.1(o) have been carried out
satisfactorily, the incoming and outgoing cables can be connected. Ensure that the cables are
suitably anchored or positioned so as to prevent undue tension or twisting of the cable under
operating conditions. All explosion protection requirements shall be observed. Once this is done,
the electricity supply can be energized.

9.1.2.15 Critical safety inspections after energization

The following critical safety inspections in (a) to (e) shall be carried out after energization of the
equipment:

a) ensure the correct operation of earth leakage tripping and earth fault lockout protection;

b) ensure correct pilot protection operation;

c) ensure that live line indication units are operative;

d) check for the correct operation of equipment; and

e) ensure that adequate lighting is available to allow for the reading of labels and the locating of
operating handles and push buttons.

9.1.2.16 Installation inspection records

All installation inspection results and results of tests performed shall be recorded and filed for future
reference and inspection.

9.1.2.17 Log book

A logbook shall be provided to record all switching operations, isolations and trip occurrences.

9.1.3 Scheduled inspections

The following scheduled inspections in (a) to (h) shall be carried out at a frequency that is in
accordance with mine-specific procedures.

a) Ensure that the transformer assembly is free from obstruction and accumulation of dust or water
and that the surface temperatures are not unduly high.

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b) Ensure that the tap change inspection access cover is secure.

c) Ensure that all inspection covers, access covers, doors, plug and socket fastening bolts are in
position and tight and that all flameproof gaps are clean, free of corrosion and that they comply
with the requirements of SANS 60079-1.

d) Check the condition of incoming and outgoing cables. Ensure that there is no twisting, undue
tension, or sharp bends, and that the cable is secure in cable glands and couplers.

e) Ensure that all statutory notices (see foreword) and fire fighting appliances are provided and in
position.

f) Ensure that all earth bonding is fitted and securely attached.

g) Ensure that the logbook is available and correctly utilized.

h) Carry out any other inspections advised by the equipment manufacturer or given in mine-specific
requirements.

9.1.4 Maintenance

9.1.4.1 Scheduled maintenance

9.1.4.1.1 Ensure correct isolation of equipment in accordance with mine-specific lock-out

procedures (see annex I), before an attempt is made to open any covers or remove any incoming or
outgoing cables.

9.1.4.1.2 The scheduled maintenance tasks given in (a) to (l) shall be performed.

a) Ensure that maintenance intervals are in accordance with approved mine-specific procedures.

b) Perform all checks described under regular inspection.

c) Ensure that incoming and outgoing sockets are free from damage, dust or moisture.

d) Inspect all MV connections and cables for signs of damage due to tracking.

e) Where possible, check all MV and LV connections for tightness and signs of overheating. Inspect
any densely packed cable trunking and take specific notice around and in the vicinity of any tight
strapping together of cables such as run locks for signs of insulation damage or overheating.

f) Where possible, inspect MV and LV bushings to ensure that they are free from damage, dust or
moisture.

g) Ensure that all tap-change link connections are secure and free from dust, moisture and signs of
overheating or tracking between phases and phase to earth.

h) Perform insulation tests between MV windings and earth, LV windings and earth (disconnect
neutral earth to perform this test), and between MV and LV windings (ensure the neutral earth
connection is re-secured after insulation tests have been performed).

i) Ensure the integrity of the neutral earthing system.

j) Inspect the switchgear associated with the transformer as described in 9.2.3.

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k) Perform any other maintenance and tests advised by the equipment manufacturer or mine-
specific standards.

l) Ensure that all periodic inspection results and results of tests performed are recorded and filed
for future reference and inspection.

9.1.4.2 Scheduled major overhaul

9.1.4.2.1 In order to facilitate major overhaul, the transformer assembly should be removed from
service and taken to a suitable workshop.

9.1.4.2.2 The scheduled maintenance tasks given in (a) to (h) shall be performed.

a) Remove all transformer covers.

b) Remove the transformer core from its enclosure,

1) remove any corrosion, dust or moisture from the core and windings, and

2) remove any corrosion, dust or moisture from the enclosure; pay special attention to the
inside corners which can be susceptible to a build-up of powder and corrosion which can
impair the flameproof integrity of the enclosure.

c) Ensure that all bracings and connections are secure after reassembly into the enclosure.

d) Ensure that all bushings are cleaned, inspected for damage and that they are insulation tested.

e) Ensure that switchgear associated with the transformer is maintained as described in 9.2.4.

f) Perform any other necessary tests specified by the manufacturer, given in legislation (see
foreword) and in mine-specific standards.

g) Perform all other inspections and tests described under periodic underground inspections.

h) Ensure that all maintenance results and test results are recorded and filed for future reference
and inspection.

9.2 Flameproof switchgear

9.2.1 General

Each mine shall have a code of practice for the following:

a) the installation of switchgear;

b) a scheduled inspection programme, which shall be carried out regularly;

c) scheduled maintenance and overhaul programmes which shall be carried out periodically; and

d) operational procedures.

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9.2.2 Installation

9.2.2.1 General

Switchgear applications in mines are exposed to severe conditions. Equipment suitability and
protection settings shall be observed, and maintenance shall be strictly carried out to safeguard
mine personnel, operating staff and equipment.

9.2.2.2 Equipment ratings

Equipment used in switchgear shall be correctly rated to withstand the full fault current and transient
surge voltages.

9.2.2.3 Clearances

Busbars, circuit-breakers, contactors, cable connections, etc. shall have clearances and insulation
as given in the specific recommendations of the equipment manufacturer.

9.2.2.4 Interlocks

Where required, mechanical or electrical interlocking (or both) shall be provided on panel doors
and, where possible, on inspection covers.

9.2.2.5 Sharp protrusions

Sharp metal protrusions shall be avoided where any insulation can sustain damage.

9.2.2.6 Cable securing devices

Any cable securing device or method that damages insulation in any way shall be avoided.

9.2.2.7 Ionization

During operation of power switching devices such as circuit-breakers and contactors, air is ionized
and therefore clearances, as required by the manufacturer for correct system voltage ratings, shall
be strictly adhered to.

9.2.2.8 Protection settings

Protection settings shall be configured and set for the specific installation.

9.2.2.9 Drawings

Electrical and mechanical layout drawings for switchgear shall be available to allow for easy
identification of components and their connection details.

9.2.2.10 Switchgear enclosures

The enclosure construction shall comply with the requirements of SANS 60079-1.

9.2.2.11 Cable connections or terminations

All cable couplings, connections and terminations shall be properly secured and the earth continuity
maintained with the switchgear enclosure.

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9.2.2.12 Equipment documentation

All IA certificates shall be available and filed, and shall prove that the correct type of explosion
protection is given for the hazardous area in which the equipment will be used.

9.2.2.13 Internal components

Once the switchgear has been positioned, all panel doors and inspection covers shall be opened to
ensure that internal components, cables and connections are in place, secure and free from
damage.

9.2.2.14 Busbar connections

All busbar and cable box connections shall be secure.

9.2.2.15 Insulation tests

Insulation tests shall be conducted before energization of the incoming and outgoing phase leads
between phases and between each phase to earth. Any electronic instrumentation shall be
disconnected to prevent inadvertent damage. The manufacturer’s instructions and recom-
mendations shall be referred to.

NOTE Insulation testing should be carried out with an approved insulation tester and testing should be done
in accordance with mine-specific standards.

9.2.2.16 Critical safety inspections before energization

The following critical safety inspections shall be carried out before energization of the switchgear.

a) Ensure that the switchgear is located in a clean, dry area which is clear of moving traffic and
where the roof and sidewalls are in good condition. The area should be such that the
accumulation of dust or water is minimized.

b) Ensure that adequate space is allowed around the switchgear to provide the following:

1) unobstructed ventilation around the switchgear;

2) easy installation and removal of incoming and outgoing cables;

3) uninhibited access to the assembly, in particular to operating handles, push buttons,

emergency stops, inspection covers, access covers and doors; and

4) free visual access to inspection windows, indication lamps and switchgear assembly
labelling.

c) Confirm the integrity of all back tripping circuits, i.e. door, cover, short-circuit back tripping
provisions and electrical interlocking.

d) Ensure that all incoming and outgoing adaptors and sockets are clean, free from damage and
secure.

e) Ensure all blanking plugs are in place.

f) Ensure that any instrument glasses and inspection windows are intact.

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g) Ensure that all panel doors, inspection and access covers are in place and correctly secured by
the correct specified bolts, which are of a proper and uniform size.

h) Ensure that all covers over reset or set buttons etc. are fitted and secure.

i) Measure the flameproof gaps to ensure compliance with SANS 60079-1.

j) Ensure that earth bonding of equipment complies with mine-specific requirements.

k) Ensure that fire fighting and statutory notices (see foreword) are available, legible and in position.

l) Ensure that the certification labels are legible and in place and that the correct explosion-
protection product certification mark is displayed for the hazardous area in which the equipment
will be used.

m) Carry out any other checks or tests advised by the equipment manufacturer or given in mine-
specific standards.

9.2.2.17 Energization

Once the inspections in 9.2.2.16(a) to 9.2.2.16(m) have been carried out satisfactorily, the incoming
and outgoing cables can be connected. Ensure that the cables are suitably anchored or positioned
so as to prevent undue tension or twisting of the cable under operating conditions. All explosion
protection requirements shall be observed. Once this has been done the electricity supply can be
energized.

9.2.2.18 Critical safety inspections after energization

The following critical safety inspections in (a) to (e) shall be carried out after energization of the
equipment:

a) ensure the correct operation of earth leakage tripping and earth fault lock-out protection;

b) ensure correct operation of pilot protection;

c) ensure that any live line indication units are operative;

d) check that equipment operate correctly; and

e) ensure that lighting is available to allow for the reading of labels and the locating of operating
handles and push buttons.

9.2.2.19 Installation inspection records

All installation inspection results and results of tests performed shall be recorded and filed for future
reference and inspection.

9.2.2.20 Logbook

A logbook shall be provided to record all switching operations, isolations and trip occurrences.

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9.2.3 Scheduled inspections

The following scheduled inspections in (a) to (m) shall be carried out.

a) Ensure that the frequency of regular inspections is in accordance with mine-specific procedures.

b) Ensure that switchgear is free from obstruction and accumulation of dust or water and that the
surface temperatures are not excessive.

c) Ensure that all enclosures, inspection covers, access covers, doors, plug and socket fastening
bolts are in position and tight and that all flameproof gaps are clean, free from corrosion and that
they comply with the requirements of SANS 60079-1.

d) Check the condition of incoming and outgoing cables. Ensure that there is no twisting, undue
tension or sharp bends and that the cable is secure.

e) Ensure that ammeter readings correspond in relation to duty.

f) Ensure that there is no contactor chattering and that the contactors are quiet in operation.

g) Ensure that any reset or setting covers are secure.

h) Ensure that statutory notices (see foreword) and fire fighting appliances are provided and in
position.

i) Ensure that all earth bonding is in place.

j) Check that instruments and indicator glasses have no defects.

k) Ensure correct operation of earth leakage, earth leakage lockout, and pilot protection and any
other interlocks that might be necessary for the installation.

l) Ensure that the logbook is available and correctly utilized.

m) Carry out any other inspections advised by the equipment manufacturer or given in mine-specific
requirements.

9.2.4 Maintenance

9.2.4.1 Scheduled maintenance

9.2.4.1.1 Ensure correct isolation of equipment in accordance with mine-specific lock-out

procedures (see annex I) before an attempt is made to open any covers or remove any incoming or
outgoing cables.

9.2.4.1.2 The following scheduled maintenance tasks given in (a) to (l) shall be performed.

a) Ensure that maintenance intervals are in accordance with approved mine-specific procedures.

b) Perform all checks described under periodic inspection.

c) Ensure that all internal parts are secure on their mountings and that all cable and busbar
connections are secure.

d) Inspect all cable connections for signs of overheating.

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e) Inspect busbar chamber, main enclosure, cable boxes and busbar interconnections for signs of
overheating.

f) Ensure that all contacts are making good electrical connection and show no signs of
overheating.

g) Ensure that arc shields are in position and in good condition.

h) Ensure that overloads, short-circuit trips and earth leakage trips are set correctly for duty.

i) Ensure that indication lamps are in order and that they operate correctly.

j) Clean the interior. Use only approved cleaning agents, and ensure that the area around the
cleaning operation is well ventilated. (Some oil-based water displacement sprays attack certain
plastic materials and the oil residue allows coal dust to accumulate, which could compromise
design creepage distances.)

k) Ensure that all mechanical operations and interlocks are operative.

l) Ensure that all fuses are correctly rated, of the correct type, and intact.

m) Ensure that the voltage tap setting of control transformers is in accordance with the supply
voltage and required control voltage.

n) Ensure that all cable insulation is clean and in good order, and perform insulation tests on phase
cables.

o) Ensure that the isolator compartment is clean, all connections are secure and that there are no
signs of overheating.

p) Ensure that all electrical interlocking and back tripping is operative.

q) Ensure that all push buttons are operative and not sticking.

r) Ensure that no SF6 or vacuum contactors or circuit-breakers are damaged and that there is no
loss of SF6 gas or vacuum. Inspect circuit-breakers in accordance with the manufacturer's
recommendations to ensure that the service life and duty have not been exceeded.

s) Check that all incoming and outgoing sockets are free from damage, dust or moisture.

t) Inspect any densely packed cable trunking and take specific notice around and in the vicinity of
any tight strapping together of cables, such as run locks, for signs of overheating or damage.

u) Inspect any bushings to ensure that they are clean and free from damage.

v) Carry out any other maintenance and tests advised by equipment manufacturers or given in
mine-specific requirements.

w) Ensure that all periodic inspection results and results of tests performed are recorded and filed
for future reference and inspection.

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9.2.4.2 Scheduled major overhaul

9.2.4.2.1 In order to facilitate a major overhaul, the switchgear should be removed from service and
taken to a suitable workshop.

9.2.4.2.2 The following scheduled maintenance tasks given in (a) to (e) shall be performed.

a) Perform all maintenance described under periodic maintenance.

b) Test all safety circuits to ensure correct operation.

c) Ensure that all protective devices operate correctly and comply with original manufacturer’s
specifications, by conducting injection tests.

d) Carry out any other inspections and tests specified by the manufacturer, given in legislation (see
foreword) and in mine-specific standards.

e) Ensure that all maintenance results and test results are recorded and filed for future reference
and inspection.

9.3 Flameproof electric motors

9.3.1 General

The maintenance of explosion-protected electric motors shall be entrusted only to competent

persons who have received instruction and training in the special techniques involved.

Equipment can only remain safe if it has been selected, installed, inspected and maintained in
accordance with the manufacturers' recommendations.

Responsibility for the proper installation and maintenance of certified equipment shall rest with the
end user. Operation of certified equipment in hazardous areas shall require correct installation and
maintenance information from manufacturers.

Suppliers of certified equipment shall provide sufficient information to enable the equipment to be
installed, operated and maintained in a safe manner. Well-documented operating and maintenance
manuals are essential.

9.3.2 Installation of explosion-protected motors

9.3.2.1 Type e motors

In the case of type e motors, the conditions stipulated on the test certificate shall be observed.
These usually include the following:

a) the motor shall be used with overload protection that is sufficiently sensitive to isolate the motor
before it overheats further than the permissible limit (this overload protection might be replaced
with a temperature sensing device, when so stipulated);

b) the motor might be used for continuous service and normal, infrequent starting; and

c) the motor shall be used at the correct voltage and frequency, the ambient temperature shall not
exceed the maximum for which the motor has been certified (usually 40 ºC), and cooling shall
not be impaired by dust, dirt, proximity of other equipment, or by the use of the motor at an
altitude exceeding the altitude for which it was designed.

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9.3.2.2 Application

9.3.2.2.1 Ensure that the equipment is suitable for the purpose and the Ex certification is correct for
the application. Consider the possible presence of moisture and other corrosive agents at the site,
and, if possible, take steps to combat such agents. Where possible install the equipment so that
there is adequate space around it for easy inspection and maintenance. Provide for adequate
illumination of the equipment.

9.3.2.2.2 Ensure that the cable is brought into the enclosure or the terminal box in the manner
intended by design, that the entry hole for the cable is sealed off by means of a cable gland, applied
in accordance with the manufacturers' instructions and the cable cores connected to the equipment
in the correct manner. This is especially important in type e equipment.

9.3.3 Automatic electrical protection and earthing

9.3.3.1 Ensure that protective devices, where installed, are kept in proper working condition. Use
only circuit-breakers of the free handle trip-free type to prevent spragging of circuit-breakers. In the
installation of earth leakage protection, reduce the risk of back tripping by grading and, where
applicable, the setting and time grading of this protection in relation to any other protective devices
which might be employed.

9.3.3.2 Bond the armouring, metallic sheathing, screening, or earth cores of cables solidly and
permanently to earth, to prevent incendive sparking by induced currents. For the same reason,
ensure that earth cores are arranged symmetrically relative to power cores, and that the impedance
of each core to earth is approximately the same, unless it has been shown by test that the current
levels in the cable are at such a low level as to preclude dangerous induced voltages.

9.3.4 Inspection

9.3.4.1 Inspections should be carried out by competent persons and the results of the inspections
shall be recorded.

9.3.4.2 Physical and visual inspections shall be carried out. Inspections shall form an integral part
of the mine’s maintenance scheme. The type and frequency of the inspections shall be determined
by the duty of the equipment and shall be in accordance with the manufacturer’s recommendations.
The following shall be adhered to:

a) Observe the statutory requirements (see foreword) relating to inspections and tests in danger
areas. Do such tests in accordance with a definite testing routine, at such intervals as are
determined by statutory regulations (see foreword) or by the approving authority, or at such
intervals as are shown necessary by experience, whichever are the shorter intervals. Keep a
permanent record of such tests. Tests shall be done in accordance with the maintenance
scheme laid down by the mine or by a scheme from the manufacturer of the equipment.

b) Do not open any equipment, other than intrinsically safe equipment, until it has been
disconnected at the source of supply and made safe. Ensure that it cannot be reconnected
before it is reassembled. (Isolate, lock out, and test before commencing with work.) Where a
heavy rotating plant is involved, the back electromagnetic force should be taken into account.
Precautions shall be taken to ensure that equipment is not opened until the rotating plant is
stationary.

9.3.5 Maintenance
The continued safe operation of electric motors depends on the electric motor being maintained to
ensure compliance with the design and certification parameters, in accordance with the

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manufacturers' recommendations. The replacement or repair of parts shall be in accordance with

the relevant certification and manufacturers' recommendations.

9.3.6 Protective devices

The windings of Ex e motors shall be protected by suitable devices to ensure that the specified
design temperature limits cannot be exceeded. The manufacturers' recommendations regarding the
type of protective device that might be used, and the settings of such a protective device shall be
adhered to at all times. The recommendations of the manufacturer shall be available for all
inspections.

9.3.7 Increased safety (Ex e) motors

Increased safety motors are not contained in a flameproof enclosure. Consequently, any internal
ignition of methane will result in an ignition of the gas outside the motor. In order to prevent this
occurrence, the surface temperatures inside the motor shall be strictly controlled. This type of
control can only be achieved by means of temperature detectors mounted at various places inside
the motor. The detectors shall feed an over-temperature tripping device in the switch panel.

Thus, standard gate-end boxes used for feeding flameproof motors shall not be suitable for
increased safety motors.

9.4 Variable speed drives (VSDs)

9.4.1 General
9.4.1.1 Variable speed drives often operate at high temperatures and rely on large heat sinks or
other methods of cooling. Systems operated outside of design parameters will result in overheating
of the drive which might cause an ignition of methane or coal dust. Other considerations are
overheating of the motor at low speeds due to the reduced effect of cooling fans, and the possible
further reduced cooling effect of air at high ambient temperatures such as might be found in hard
rock mines or at high altitudes where the air is thinner and has a reduced ability to remove heat
from both the motor and the drive. At high altitudes (above 1 000 m), the manufacturer’s de-rating
tables for both the motor and the drive shall be consulted. De-rating tables might also be available
for motors used in ambient temperatures above 40 °C.

9.4.1.2 Due to these temperature considerations, over-temperature protective devices shall be

fitted and connected at all times. Disconnection or shorting out of these devices might induce
premature failure and the possibility of an explosion as previously described, but might also make
the relevant test laboratory certificate for the motor or system null and void.

9.4.1.3 The VSD and motor shall be certified as a complete system.

9.4.1.4 The use of pulse width modulation (PWM) variable speed drives with high switching
frequencies and fast voltage rise times changes the stresses applied to the motor by the drive.
While the emphasis on heating due to the harmonic effect has been much reduced, the need for
adequate cooling during low speed operation, however, remains.

9.4.1.5 The condition in 9.4.1.4 gives rise to a new factor, high-voltage peaks, seen at the motor
terminals at the switching frequency. The voltage peaks arise from rapid voltage rise time and are a
function of the input voltage to the drive, the motor rise time, the length of the cable from drive to
motor and the characteristics of the cable used. The motor characteristics have virtually no effect on
the voltage peaks.

9.4.1.6 The voltage peaks measured may be as much as 3,2 times greater than the input r.m.s. line
to neutral supply voltage to the drive.

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9.4.1.7 Due to the inherent fast voltage rise times associated with solid state drives, the insulation
levels of the motor can be stressed. The insulation stress levels are a function of the input supply to
the drive and the cable length. This should be taken into account when installations are designed.

9.4.2 Installation

9.4.2.1 Cable length between the motor and drive output shall be minimized and shall comply with
the manufacturer’s recommendations.

9.4.2.2 In the case of new installations, the insulation system might be designed to give reliable
service in the presence of voltage peaks. An alternative is to use filters to limit the voltage peaks
and rise times at the motor.

9.4.2.3 Thermal protection of any motor is extremely important, as excessive heat will accelerate
motor insulation deterioration and cause premature insulation failure. Excessive heat might also
cause breakdown of bearing grease, thus damaging the bearing system leading to catastrophic
mechanical failure of the motor. The motor temperature is partly made up of two components: the
internal temperature rise and the external ambient temperature. The surface area of the motor shall
be kept clear of any build-up of mineral or dirt that will have the effect of increasing the motor
temperature. In hazardous areas, the surface temperature of the motor is important and, if not
controlled, might lead to ignition of methane or coal dust.

9.4.2.4 An internal fan, part of the motor assembly, generally maintains cooling, but if the motor is
run at low speeds for long periods, an external fan might be utilized. Where these methods are
inadequate, water-cooling of the motor might be an alternative. Whatever the method, it shall be
fully functional at all times.

9.4.3 Earthing

9.4.3.1 Under normal conditions where a three-phase supply is balanced and symmetrical, the
neutral point of a system is at zero volts. However, with modern PWM drive systems, the inherent
switched three-phase power supply prevents an instantaneous balance between phases. This
causes what is termed as a "common mode voltage" to appear between the drive output and earth
which, in turn, causes currents to flow through stray impedances in the motor cables and windings.

9.4.3.2 In large motors (above 100 kW), high frequency bearing currents are induced in the motor
shaft due to asymmetrical flux distribution in the motor. Voltage pulses fed by the VSD contain such
high frequencies that the leakage capacitances of the motor windings provide paths for currents to
leak to earth. This induces a voltage between the shaft ends, and should this voltage be high
enough to overcome the impedance of the oil film of the bearings, a circulating bearing current
occurs. When the leakage current returns to the inverter through the earth path, it tends to seek the
paths of lowest impedance. If the motor shaft is earthed through the driven load, part of the leakage
current will flow through the bearings, shaft and load back to the inverter. This particular leakage
current is termed "shaft-earthing current".

9.4.3.3 In smaller motors (less than 30 kW) and where the shaft is not earthed through the load, the
relative sizes of internal stray capacitances might cause internal division of the common mode
voltage such that shaft voltages generated might be high enough to create high frequency bearing
current pulses.

9.4.3.4 High frequency bearing current pulses might lead to bearing failures and the possibility of
high touch potentials that lead to electric shock.

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9.4.3.5 These dangers might be prevented by applying the following three good engineering
practices:

a) Ensure a proper cabling and earthing system

1) Use symmetrical multi-core motor cables. The earth conductor shall be symmetrical to avoid
bearing currents at fundamental frequency. The symmetry can be achieved by a conductor
that surrounds all the phase leads or a cable that contains symmetrical three-phase power
conductors and three earth conductors.

2) Ensure that the earth return path is as short and impedance as low as possible between the
VSD and the motor so that the common mode current might return to the VSD. The best
practice is to use shielded motor cables; the shield shall be continuous and of good
conducting material such as copper. The connection at each end of the cable shall be made
with a 360° termination, as shown in figure 1.

3) Where possible, use high frequency bonding connections between the installation and known
earth reference points to equalize the potential of affected equipment. The use of braided
straps of copper 50 mm to 100 mm wide provides a lower inductance path than round wires.

Figure 1 — 360° cable termination

b) Break the bearing current loops

Break the current loop by insulating the non-drive end bearing thus insulating the shaft from the
motor frame, or by using an insulated coupling between the motor and the driven load.

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c) Dampen the common mode current

Dampen the high frequency common mode current by using dedicated filters, which add impedance
in the common mode loop.

9.4.4 Maintenance

9.4.4.1 AC variable speed drives (VSD) use large capacitors in their d.c. circuit, and after switching
off a VSD, several minutes might be required before the opening of an explosion-protected
enclosure for sufficient discharge. Most modern VSDs have some form of indication to show when
the capacitors are discharged.

9.4.4.2 For correct operation, a VSD should have its settings checked and monitored for optimum
performance, which will help avoid unnecessary heat generation. Some of the settings available on
modern VSDs might include:

a) unit base voltage and base frequency;

b) maximum and minimum motor speeds;

c) rated motor current (should not exceed maximum drive current rating); and

d) acceleration and deceleration times.

9.5 Lighting and luminaires

Lighting used in mines falls into four categories as given in (a) to (d).

(a) Machine lighting

Machine lighting generally consists of headlights (tungsten halogen) to illuminate in front and at the
rear of the vehicle and to enable and assist the operator to see the working area, objects and
personnel. Visual warning lights (xenon or flashing LEDs) alert personnel in the vicinity of the
machine. The lights will be explosion protected if fitted onto a vehicle used in the hazardous area of
the mine.

(b) Roadway lighting

Roadway lighting generally consists of fluorescent or compact fluorescent luminaires (or both)
installed along the main travelling roads, belt transfer points and, in some instances, along the belt
roads. These lights are not explosion protected as they are outside the hazardous area.

(c) Working area lighting

Working area lighting is generally undertaken utilizing fluorescent light-fittings mounted above the
feeder breaker or coal tip tail end of the section belt or at the miner's box mounted to the electrical
switchgear and transformers. In the case of a long-wall, mining lighting is mounted on the hydraulic
roof supports, stage loader or crusher, removal van and the tail end of the section belt. The working
area is a hazardous area and the lighting shall be certified explosion-protected. Most common
protection concepts are flameproofing Ex d, increased safety Ex e or intrinsically safe Ex i.

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(d) Visual warning lighting

Visual warning lighting equipment consists of flameproof and intrinsically safe flashing lights that
might be xenon or LED electronic flashing units, either vehicle or machine mounted, roof or fixed
structure mounted. In non-hazardous areas, industrial units are generally used.

NOTE For information on stroboscopic lights, see "stroboscopic effect" in 3.1.66.

9.5.2 Installation

9.5.2.1 General

During installation, the manufacturers' recommendations and area classification or certification of

the unit shall be adhered to.

9.5.2.2 Earth leakage protection

Lighting circuits in hazardous areas supplied from a nominal 220/110 V a.c. supply shall have a
source that is earth-leakage protected, rated at 30 mA maximum.

9.5.2.3 Environmental conditions

Luminaires with appropriate IP ratings shall be used for fittings in extremely humid, damp or dusty
conditions (see SANS 60079-31 and SANS 61241-0).

9.5.2.4 Unused cable entries

Cable entries provided on the luminaire that are unused shall be closed by the use of a proper
screwed stopper plug of an approved certified design. Failure to do this will invalidate the
certification of the unit.

9.5.2.5 Temperature

All light sources generate heat, both from the light source itself and, where relevant, from its
associated controlgear. This might affect the choice of luminaire, as the attained surface
temperature (T-rating) might not allow the use of some luminaires.

9.5.2.6 Lamp service period (life)

Life, when applied to electric lamps, has two distinct meanings

a) the time after which the lamp ceases to operate, and

b) the time after which the light output is reduced to such a low level that it is economic to replace
the lamp.

9.5.2.7 Illuminance

Areas of extreme danger shall be well illuminated, for example, transfer points, moving machinery
boarding and alighting places or as designated by the employer (see SANS 10114-1).

NOTE See the mine-specific requirements.

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9.5.2.8 Glare

Glare occurs when light sources or luminaires (or both) seen either directly or by reflection are too
bright compared to the general brightness of the surrounding area. Glare can impair vision
(disabling glare) and cause visual discomfort (discomfort glare). In order to reduce glare, luminaires
shall not be directed towards a person so that they are in his normal line of sight. Fluorescent
luminaires have lower levels of luminance and can generally be mounted at low heights without
causing glare.

9.5.3 Inspection and maintenance

Regular maintenance and inspection shall ensure that luminaires and associated equipment are
installed in accordance with the manufacturers' recommendations. When lighting equipment is
being inspected and maintained, the points in (a) to (i) shall be taken into account:

a) Corrosion, vibration or mechanical impact damage. This might render the unit unfit for
purpose and invalidate any explosion-protection standard and certification.

b) Damaged light-transmitting parts. Where polycarbonate lamp glasses (lenses) are used, care
shall be taken that chemicals or cleaning agents do not attack the lamp glass.

c) Damaged or missing fasteners. These shall be replaced with items of the correct quality and
specified material. Fasteners shall not be over-tightened. Overstressing of glass or plastic
components shall be avoided.

d) Ingress of coal dust. Missing or damaged gaskets shall be immediately replaced with the
correct item to avoid the ingress of coal dust. On items with e type certification, gaskets form a
required part of the standard and certification.

e) Loose mounting brackets. These are generally overlooked.

f) Terminations. Cables shall be properly terminated using the correct certified cable glands, plugs
and connectors. All luminaires shall be effectively earthed and all terminals and conductors
cleaned and tight, earthed continuity shall be maintained between incoming and outgoing cables
and connections.

g) Flameproof paths for pitting and flameproof path clearance. During maintenance all
flameproof paths and threaded components should be lightly greased with an approved form of
non-setting grease. Care shall be taken that blind tapped holes are free from dirt or excessive
grease.

h) Planned lamp replacement. The replacing of faulty lamps reduces the possibility of failure of
the controlgear, and improves efficiency.

i) Luminaires. These shall be installed in accordance with the requirements of the installation,
particularly the classification of the area and the manufacturer’s recommendations. The correctly
rated lamp shall be fitted and shall be working. Modifications shall not be made to any fitting or
component.

9.6 Electric cables

9.6.1 Environmental and operational factors

9.6.1.1 When a power reticulation system and its component parts are being designed, due
account shall be taken of the environment, including mechanical, chemical and thermal factors.

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9.6.1.2 Cables and conductors shall be acceptable for the environment, conditions of use, voltage
of the circuit, size of load and potential fault levels.

9.6.2 Fire and associated hazards related to underground cable installations

Underground cable installations in mines present a significant fire hazard. The risk of a cable
installation igniting and causing a fire can be attributed to the following:

a) The ignition source could be external to the cable installation.

b) Faulty setting or malfunction of protective devices could lead to the ignition of a cable. The
primary cause in this instance could be overcurrent or a short-circuit condition. If the cable is
loaded beyond the designed current rating, overheating of the conductors and insulation
materials will take place. If this condition is such that the ignition point of the cable insulation
material is exceeded, the cable will burn.

c) The operation and setting of protective devices are critical in the prevention of uncontrolled
energy release under fault conditions. If the short-circuit rating of a cable is exceeded, the cable
will rupture and burn. Protective devices that are incorrectly set or inoperative will increase the
probability of ignition of the cable under fault conditions.

9.6.3 Primary hazards associated with cable fires underground

Standard cable types manufactured from PVC (polyvinyl chloride) compounds release a range of
toxic products once they are ignited. These toxic products can be fatal, depending on the nature
and time of exposure. The main toxic products associated with cable fires are:

a) Carbon monoxide. The major cause of death in fire accidents is primarily carbon monoxide
poisoning or alternatively asphyxia associated with oxygen depletion in the surrounding air.

b) Hydrogen chloride (acid) gas. The primary physiological effect of the liberation of this gas is
severe irritation of the eyes, nasal passages and throat. This condition can lead to disorientation
and panic.

The secondary effect is economic; exposure will lead to premature failure of electronic
equipment that has been exposed to the gas.

c) Smoke emission. In underground mining conditions, smoke emissions from burning materials
can affect large areas due to the nature of mine ventilation systems. Subsequently, large
numbers of people can be exposed to smoke emissions. The main problem associated with
smoke emission, apart from the toxic materials released, is restricted visibility. The restricted
visibility promotes disorientation and can inhibit persons accessing safe areas such as rescue
bays.

9.6.4 Methods of minimizing the risks associated with cable fires underground

The hazards in 9.6.3(a), (b) and (c) and risks associated with underground cable fires can be
minimized by utilizing the technologies in the following (a) to (c).

a) Flame retardant cables. These cables are designed to limit flame propagation and minimize
toxic gas emissions. The cable material has chemical compounds that are formulated to achieve
lower toxic and smoke emissions, and also lower flame propagation. Non-halogenated cable
types present the lowest fire risks.

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b) Intumescent coatings. These coatings are normally water based and designed to prevent flame
propagation along the external sheath of a PVC cable. In addition, they provide a thermal
insulation barrier to the cable, protecting the cable against external sources of heat. This thermal
insulation, however, shall be taken into account and the cable should be de-rated to take into
account the reduced ability of the cable to radiate internal heat into the surrounding air. A number
of factors shall be taken into account when intumescent coatings on cables are used.

1) Some intumescent coatings are susceptible to environmental conditions such as humidity,

ultraviolet rays and operational heat that can seriously negate the flame-retardant
performance after installation.

2) Some types of intumescent coating have problems with longevity and smoke emission
levels.

3) When intumescent coatings are used as fire breaks along the length of an underground
cable installation, the velocity of the ventilation shall dictate the length of the firebreak over
the cable. The higher the velocity, the longer the firebreak in order to eliminate the
possibility of flame that jumps the firebreak.

c) Colour coding identification of low-voltage cables. Low-voltage cables have a colour coding
system that enables identification of the fire properties associated with a particular cable
construction. The external sheath has a coloured stripe that identifies the cable properties. The
construction and properties are in accordance with the provisions given in table 2.

Table 2 — Colour coding of low-voltage cables

1 2 3 4
Colour of stripe Dielectric Bedding Sheath
No stripe Conventional PVC Conventional PVC Conventional PVC
Red Conventional PVC Conventional PVC Flame-retardant PVC
Orange Conventional PVC Flame-retardant PVC Flame-retardant PVC
Blue Conventional PVC Low-halogen PVC Low-halogen PVC
White Non-halogen Non-halogen Non-halogen

The information in table 2 indicates that the no stripe cable shall be used in the highest hazard
areas in underground mines, and the white stripe cable in the lowest hazard areas.

9.6.5 Power cables for fixed installations

The insulated power cores of cables used in fixed installations in a mine, including those within a
hazardous area, shall be individually screened and collectively covered with an inner polymer
sheath, which in turn shall be covered with steel wire armouring which in turn shall be covered by
an outer polymer sheath. Power cables shall have at least four cores: three phase cores and one
earth core. The cables shall be provided with one or more insulated pilot conductor to facilitate the
earth conductance monitoring circuit.

NOTE Individually screened cables in fixed installations should be provided with pilot conductors. These
provisions have been introduced to reduce the risk of phase-to-phase short circuits and to provide earth
conductance monitoring within a cable. All cables installed before publication of this standard should be
provided with other means of reducing the risk of a phase-to-phase short circuit and earth conductance
monitoring.

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9.6.6 Medium-voltage cable selection

9.6.6.1 General

Underground electrical power is normally reticulated at medium-voltage at 6,6 kV or 11 kV. Cable

selection for underground reticulation systems should be undertaken with the objective of reducing
the potential hazards associated with cable installations in explosive atmospheres.

9.6.6.2 Types of medium-voltage cable

9.6.6.2.1 Paper-insulated lead-covered steel wire or tape armoured (PILCSWA) cable

The following should be noted.

a) This type of cable has largely been superseded by polyethylene and PVC cables in underground
collieries.

b) The thermal limit of a PILCSWA cable is 160 °C. Continuous operational temperatures of 70 °C
are permissible.

c) The permissible 1 s symmetrical short-circuit current is 10,9 kA for a 95 mm2 cable.

d) The maximum short-circuit temperature for the conductor is 250 °C.

e) Paper-insulated cable shall be manufactured in accordance with SANS 97.

9.6.6.2.2 Polyvinyl chloride (PVC)

This type of cable is available for medium-voltage applications but has certain limitations. PVC is
classed as a thermoplastic and the following should be noted.

a) The normally acceptable threshold voltage operating level of PVC cable is 1 000 V.

b) The cable utilized on a 6,6 kV duty has increased insulation resistance as a result of the different
chemical composition of the PVC.

c) The thermal limit of PVC cable is 105 °C.

d) Continuous operating temperatures of 70 °C are permissible.

e) The maximum short-circuit temperature for the conductor is 160 °C.

f) The permissible 1 s symmetrical short-circuit current is 13,6 kA for a 95 mm2 cable.

g) The cable is not water blocked. Water blocking prevents premature failure due to water ingress.
The inclusion of water in the insulation lowers electrical resistance thus increasing the
conduction current. This condition increases the number of free electrons in the insulation
material, increasing the tendency for ionization.

h) If a PVC cable reaches ignition point, it burns, releasing dense smoke together with hydrochloric
acid and dioxins.

i) The cable design is such that it will have a relatively short life in terms of the insulation.

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j) This cable is normally recommended for temporary installations.

k) PVC cable shall be manufactured in accordance with the relevant part (parts) of SANS 1507.

9.6.6.2.3 Cross-linked polyethylene (XLPE)

Cross-linked polyethylene is more commonly installed in underground medium-voltage installations

for the reasons given in (a) to (g).

a) Cross-linking the polyethylene improves the physical and electrical properties of the cable.

b) Water blocking can be specified (which is good engineering practice).

c) The thermal limit of XLPE cable is 130 °C.

d) Continuous operating temperatures of 90 °C are permissible.

e) The maximum short-circuit temperature for the conductor is 250 °C.

f) The permissible 1 s symmetrical short-circuit current is 13,8 kA for a 95 mm2 cable.

g) XLPE cable shall be manufactured in accordance with SANS 1339.

9.6.7 Power cables that supply mobile mining machinery

9.6.7.1 Power cables shall comply with the following minimum requirements:

a) the cable shall be constructed electrically symmetrical;

b) sheathing shall be flame retardant; it shall have high tear and impact strength, and it shall be
resistant to abrasion, oil and grease;

c) the conductors shall be multi-stranded tinned copper conductors; and

d) the conductor cores shall be individually screened.

9.6.7.2 Power cables that supply power to mobile machinery in the hazardous area of a mine shall
be of the flexible tough rubber sheath trailing type of cable. The phase conductors shall be
individually covered by means of a conductive (metallic or non-metallic) screening material and
shall be provided with one or more insulated pilot cores to facilitate the use of earth conductance
monitoring (pilot) circuits.

9.6.7.3 SANS 1520-1 and SANS 1520-2 cover requirements for trailing cables for use in mines..
SANS 1520-1 covers voltages up to 3,3 kV and SANS 1520-2 voltages up to 33 kV.

9.6.7.4 When cables are used with one or more layers wound on a reel, the current rating shall be
corrected in accordance with SANS 1520-1 and SANS 1520-2 and the manufacturer's
recommendations.

9.6.7.5 The current rating of the power conductors in all trailing cables shall be not less than the
current requirement of the r.m.s. of the connected load.

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9.6.8 Mobile machinery control cables

9.6.8.1 Control cables shall comply with the following minimum requirements:

a) the conductors shall be multi-stranded conductors;

b) the conductor cores shall be collectively screened and mechanically protected; and

c) the cables shall be fire retardant and resistant to abrasion, oil and grease.

9.6.8.2 Control cables that contain Ex i circuits need not be provided with additional mechanical
protection. However, consideration should be given to the practical need to ensure serviceability,
which might justify additional mechanical protection.

9.6.8.3 Ex i and non-Ex i circuits shall not be mixed in one multi-core cable.

9.6.8.4 Cables shall be selected taking into account the diametrical tolerances and the necessary
roundness to ensure the integrity of flameproof seals when they enter flameproof enclosures
through a flameproof gland or similar sealing device.

9.6.9 Cables for portable and transportable electric machinery

9.6.9.1 Portable and transportable electric machinery, such as hand-held drills and submersible
pumps, shall be supplied with a flexible tough rubber sheath trailing cable of design similar to that of
the cable for mobile machinery, but with a minimum cross-sectional area of 4 mm2.

9.6.9.2 Submersible pumps or any other equipment that operates at a potential of 110 V and higher
and supplied by a flexible trailing power cable shall be provided at the source end of the cable with
earth fault protection so that, in the event of an earth fault, the current will be automatically isolated
and will not be restored until the earth fault has been removed.

9.6.10 Flexible trailing cables

Flexible trailing cables and their terminations are particularly prone to damage. They shall be
inspected at regular intervals. The maximum number of repairs per length of cable as determined
by regulations (see foreword) shall be observed.

9.6.11 Earth fault currents

9.6.11.1 Cable selection shall take into account the cable design with regard to its ability to handle
earth fault conditions. Cables for use in underground explosive atmospheres shall have steel wire
armouring and also individual conductor metallic screens. The steel wire armouring and the
conductor screens shall be earthed. The cable shall be able to carry high earth fault currents.

9.6.11.2 Cable that is not armoured but has individual metallic screens is available. The fault
current is limited to 1 000 A for 1 s. This type is not recommended.

9.6.12 Cable terminations

Medium-voltage cables shall be properly terminated by making use of stress-control techniques.

The prime objective of the proper termination of cables is to limit the voltage stresses at the
termination to below the corona starting voltage. Corona results in insulation degradation over time
which will lead to ionization and catastrophic failure.

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9.6.13 Cable jointing

Cable runs shall, where practical, be uninterrupted. Where discontinuities cannot be avoided, the
joint, in addition to being mechanically, electrically and environmentally suitable for the situation,
shall

a) be made in a flameproof enclosure or an enclosure with increased safety, and

b) providing the joint is not subjected to mechanical stress, be resin filled.

9.6.14 Connection of cables and conductors (flameproof)

9.6.14.1 General

Two entry methods for connecting cables and conductors are normally applied:

a) indirect entry, commonly by means of an increased safety type terminal box connected to the
flameproof enclosure by means of a bushing with separately encapsulated cores; and

b) direct entry, into the enclosure.

Precautions shall be taken against the undue disruption of the connections, when the cable is pulled
or twisted in service.

When conduit entries are used, additional information shall be obtained. Conduit entries are
normally sealed off by means of compound filled boxes. One of the reasons for this is to prevent
pressure piling into the conduits.

9.6.14.2 Indirect entry

The terminal box shall comply with flameproof requirements for entry into the main enclosure.

When a plug and socket or adaptor and half-coupler configuration is used, the units shall be
approved and the flameproof characteristics of the flameproof enclosure shall be maintained, with
the plug removed.

NOTE Always ensure that bolts, cable entry devices (direct and indirect) and blanking elements are of the
correct type and are complete and tight.

9.6.14.3 Direct entry

This is normally achieved by means of approved packing glands, plugs and sockets or adaptors and
half couplers that comply with the requirements for the flameproof enclosure.

When a plug and socket or adaptor and half-coupler configuration is used, the units shall be
certified and the flameproof characteristics of the flameproof enclosure shall be maintained, with the
plug removed.

When the cable is sealed into the enclosure, at least 1 m of the cable shall be attached to the
enclosure.

NOTE Always ensure that bolts, cable entry devices (direct and indirect) and blanking elements are of the
correct type and are complete and tight

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9.6.15 Cable conduit systems

Cable conduit systems are not used in South Africa and specialized advice shall be sought when
these systems are encountered.

It is common practice, however, to protect cables on-board mobile mining machines by installing
them inside tough rubber flexible hoses or sheaths. This affords them additional outer protection
from physical damage.

9.6.16 Inspection and repair of cables

9.6.16.1 Every trailing cable in use shall be

a) tested by the mine electrician at intervals, in accordance with the mine-specific requirements,
and

b) examined externally at the commencement of each shift by the machine operator to ensure that
the cable is mechanically sound and free from damage to the outer sheath.

9.6.16.2 When cable-handling systems are employed, the handling system shall be examined
before the commencement of each shift.

9.6.16.3 Trailing cables that have been found defective, or damaged, or have caused the protective
devices to trip, shall be isolated and removed from the supply.

9.6.16.4 A cable that has been mechanically damaged shall be permanently repaired or replaced.

9.6.16.5 Trailing cables shall be repaired in such a manner that

a) the conductivity and mechanical strength of the conductors is not reduced,

b) the conductor’s insulation has a dielectric mechanical strength equivalent to that at any other
section of the cable, and

c) equivalent protection is provided by the insulation as a substitute for the original outer sheath.

9.7 Couplers and connectors

9.7.1 Cable entry devices
The check for tightness of cable entry devices in a close inspection can be done by hand without
the need to remove weatherproofing tape or shrouds. Detailed inspections might necessitate that
the cable entry devices be dismantled.

9.7.2 Plugs, sockets, couplers and glands

9.7.2.1 Plugs, sockets, adaptors, half couplers and glands used in conjunction with explosion-
protected equipment shall comply with the applicable requirements mentioned in 9.6.14.3 for direct
cable entry systems, and also with the recommendations of the manufacturers of these devices.

9.7.2.2 Plugs, sockets, couplers and glands shall be visually inspected for damage to screw
threads, sealing rings, conducting pins or tubes, flame paths and insulating material before each
insertion into a mating part.

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9.7.2.3 Maintenance of plugs, socket, couplers and glands shall be limited to replacement of parts
obtained only from the OEM or his agent. The use of pirate parts is not permitted since this practice
will invalidate the certification.

9.7.2.4 Restrained and bolted plugs and sockets shall comply with the requirements of the relevant
part (parts) of SANS 1489.

9.7.2.5 Cables glands shall comply with SANS 808.

9.7.2.6 Where the connection of cables to electrical equipment is made with either type Ex d or
type Ex e cable glands (depending on the type and classification of the entry system used), the
glands shall fit tightly onto the cable as specified in SANS 62444 to ensure flameproof seal integrity
and to assist in the prevention of the passage of liquids or dusts past the gland seal or through the
inside of the cable.

9.8 Intrinsically safe equipment or systems

9.8.1 General
9.8.1.1 Only a competent person shall carry out the installation, inspection and maintenance of
intrinsically safe equipment.

9.8.1.2 No modification shall be made to intrinsically safe equipment except by the OEM, and the
modification shall be approved by an accredited test laboratory.

9.8.1.3 The overhaul or repair of intrinsically safe equipment shall be done in accordance with the
requirements of SANS 10086-3. This includes having the repaired unit evaluated, tested and
approved by an accredited test laboratory.

9.8.1.4 The interconnection of intrinsically safe equipment, including the interconnecting parts (for
example, cables), constitutes an intrinsically safe system. An accredited test laboratory shall
approve the system.

9.8.2 Installation and inspection

9.8.2.1 General

A certificate of intrinsic safety might apply to a single item of hand-held equipment, a single item of
equipment that can be connected to an approved or certified power source, or to a complete system
that comprises several items of equipment.

For the necessity of safe installation and maintenance of intrinsically safe equipment, the
manufacturer has a particular responsibility to provide the relevant information. The supplier shall
always be contacted in the event of any queries.

9.8.2.2 Documentation

The documentation for the equipment or system shall include the following minimum documents
and details:

a) the certification documents and documents required by SANS 60079-0;

b) details of the marking, the manufacturer, the type and certificate numbers of equipment, the
intrinsic safety category, the group and the temperature class of equipment; and

c) details of any special conditions of safe use (X) of the equipment or system and methods for
testing compliance with the requirements for the particular installation.

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9.8.2.3 Labelling

Labels on the intrinsically safe equipment or system shall be inspected to ensure that they are
legible and comply with the requirements in the certification documentation, and to ensure that the
equipment actually fitted is that specified.

9.8.2.4 Frequency of inspections

Intrinsically safe equipment or systems shall be inspected at regular intervals in accordance with
mine-specific requirements so as to ensure the integrity of the equipment, parts, components and
the installation on which the intrinsic safety depends.

9.8.2.5 Interaction with other techniques

Intrinsic safety is often used in conjunction with other types of explosion protection, for example,
where an intrinsically safe power supply is installed inside a flameproof enclosure. Interaction of the
different techniques should be considered, examples of which are given in (a) to (c).

a) Intrinsically safe equipment is certified for an ambient temperature of -20 °C to 40 °C unless

otherwise stated. When the equipment is used in a flameproof enclosure, this ambient
temperature might be exceeded, and the certification of the equipment will be invalidated.

b) Cable entries into or exits from flameproof enclosures should take cognizance of the type of
cable used, which should be suitable for use in conjunction with the flameproof gland, or this
might invalidate the flameproof characteristics of the enclosure.

c) Where a large capacitor or a battery exists in associated equipment (for example, an intrinsically
safe power supply) this might require a specific delay in the opening of the flameproof enclosure
after isolation of the power to the enclosure. This is considered by an accredited test laboratory
when the approval is being done, and a warning label might be required on the flameproof
enclosure.

9.8.2.6 Intrinsically safe systems

9.8.2.6.1 Fixed equipment

9.8.2.6.1.1 Before installation, equipment shall be checked for any possible transit damage.
Generally, fixed equipment is provided with a robust enclosure which can withstand a certain
amount of rough handling. This is not the case with the interior, and the interior shall be visually
examined to ensure its integrity.

9.8.2.6.1.2 Equipment shall be mounted in such a manner that the likelihood of it becoming
damaged is minimized. Covers and their seals shall be intact and secured to prevent contamination
from the environment. IP54 is often a requirement for intrinsically safe equipment used underground
and therefore the intrinsic safety depends upon the integrity of the enclosure and seal.

9.8.2.6.1.3 The installation shall comply with the system certification.

9.8.2.6.2 Interface devices between intrinsically safe and non-intrinsically safe circuits

Safety barrier installations shall be inspected to ensure that the correct types of barrier have been
used and that all such devices are firmly fixed to the barrier earth bar in a manner that ensures
good earth continuity. Installations shall be inspected to ensure that relays installed on moving
equipment and which act as safety barriers between the moving equipment and other devices have

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not become damaged by repeated operation or vibration, thus reducing the segregation originally
afforded.

9.8.2.6.3 Cables

9.8.2.6.3.1 Installations shall be inspected to ensure that the cables used comply with the
certification documentation, especially with regard to construction, specification, and capacitance
and inductance values.

9.8.2.6.3.2 When intrinsic safe equipment is repositioned, care shall be taken when the length of
any cable, which forms part of the approved or certified system, is increased, that the additional
capacitance and inductance do not violate the requirements of the safety parameters.

9.8.2.6.3.3 Intrinsically safe circuits and non-intrinsically safe circuits shall not be run in the same
multi-core cable.

9.8.2.6.3.4 The integrity of cable connections to intrinsically safe equipment shall be inspected.
Cables to and from intrinsically safe equipment shall be inspected for damage.

9.8.2.6.3.5 Particular attention shall be paid to separation, insulation, etc., where cables, which
contain intrinsically safe systems, and other cables are run in the same pipe, duct, cable tray or are
bundled together. This includes the inside of flameproof enclosures.

9.8.2.6.4 Cable screens

Installations shall be inspected to ensure that cable screens are earthed in accordance with the
appropriate system certification documentation. The screens of cables associated with intrinsically
safe equipment are usually solidly connected to the high integrity or quality earth at one point in the
safe area or flameproof enclosure. This earthing shall be continuous through junction boxes but is
not connected to the hazardous area equipment in general.

9.8.2.6.5 Point-to-point connections

This check is only required at the initial inspection.

9.8.2.6.6 Earth conductance

The conductance of the high integrity earth connection between intrinsically safe circuits and the
earth point shall be measured or tested by means of an earth conductance monitoring circuit at
initial inspection and at regular intervals as required by the mine-specific inspection or maintenance
schedules. The measurement method and instrument should consider the associated risk when
being used in a hazardous area.

9.8.2.6.7 Intrinsically safe circuit earthing or insulation

The insulation testing of intrinsically safe circuits is necessary to confirm that they are earthed or
insulated from earth throughout, whichever of these conditions is required by the original design.

Insulation testing of circuits of intrinsically safe systems shall be carried out with due regard to the
associated risk when being conducted in a hazardous area. In order to carry out these tests, the
normal earth connection shall be disconnected. This can only be done if either the area is declared
free from hazard, or if power is completely removed from the system.

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9.8.2.6.8 Separation between intrinsically safe and non-intrinsically safe circuits

Junction boxes that contain safety barriers shall be inspected to ensure that they do not contain
wiring which is not specified in the documentation appropriate to any system that passes through
them. The required separation between intrinsic safety, screens and non-intrinsically safe circuits
and also the through connection of screens shall be inspected.

9.8.3 Maintenance on intrinsically safe equipment or systems

9.8.3.1 Planning

When maintenance on intrinsically safe equipment and intrinsically safe systems are planned, the
directions and instructions of the manufacturer shall be sought and adhered to.

Maintenance work might be carried out on energized intrinsically safe equipment, subject to the
conditions detailed in 9.8.3.2 and 9.8.3.3. The applicable principles shall be applied to non-
energized intrinsically safe equipment, where applicable.

9.8.3.2 Maintenance work in hazardous areas

Maintenance work shall be restricted to the work given in (a) to (f).

a) The disconnection and removal, or replacement, of items of electrical equipment and cabling,
except the high integrity earth cable where equipment might be live.

b) The adjustment of any controls that are necessary for the calibration of the electrical equipment
or system. No settings may be changed on the electronics of intrinsically safe equipment, unless
it has been specifically allowed for by the manufacturer or by means of external setting switches
or adjustment mechanisms.

c) The removal and replacement of any plug-in components or assemblies with certified units that
do not invalidate the equipment or system certification.

d) The use of ancillary equipment as specified in the certification documentation. Where test
instruments are not specified in the relevant documentation, only those instruments that do not
affect the intrinsic safety of the circuit under test may be used. Care should be taken when
insulation testers or high-voltage test instruments are used in conjunction with intrinsically safe
circuits or cables. The high voltage might damage electronic components in the circuit and
therefore affect the intrinsic safety of the equipment or system. These test instruments shall
never be connected direct to the electronics, or parts of the circuit with direct electrical
connection to the electronics of the equipment, so as to affect a high potential difference or
voltage in the electronic circuit.

e) Consideration shall be given to any special conditions of use when intrinsically safe test
instruments are used; this shall be done before the instrument is used on intrinsically safe
equipment.

f) Any other maintenance activity specifically permitted by the relevant documentation.

9.8.3.3 Maintenance work in non-hazardous areas

Maintenance work on associated electrical equipment and parts of intrinsically safe circuits located
in non-hazardous areas shall be restricted to the work in 9.8.3.2 whilst such electrical equipment,
parts or circuits remain interconnected with parts of intrinsically safe systems located in hazardous
areas. Safety barrier earth connections shall not be removed without first disconnecting the
hazardous area circuits. Other maintenance work on associated equipment or parts of an

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intrinsically safe circuit mounted in a non-hazardous area shall be carried out only if the electrical
equipment or part of a circuit is disconnected from the part of the circuit located in a hazardous
area.

9.8.3.4 Earthing and potential equalization bonding

Care shall be taken to ensure that the earthing and potential equalization bonding provisions for
hazardous areas are maintained in good condition to comply with the approval or certification
requirements of the equipment and systems. This includes maintenance in and outside the
hazardous area.

9.8.3.5 Portable and hand-held equipment

9.8.3.5.1 Portable and hand-held intrinsically safe equipment will often have a self-contained power
source. Replacement of such power sources shall be exactly in accordance with the type(s) (and in
some cases, manufacturers) specified in the certification documents.

9.8.3.5.2 Batteries of portable and hand-held intrinsically safe equipment shall not be replaced in
hazardous areas, unless the batteries have been certified as intrinsically safe in their own right.
Such replacement batteries shall be of exactly the same type (and in some cases, manufacturer) as
was originally certified for the specific equipment.

9.8.3.5.3 The IP rating of hand-held or portable equipment is normally IP54 or better. The rating
shall be maintained.

9.8.3.6 On-site maintenance

9.8.3.6.1 Periodic examination and maintenance of the intrinsically safe equipment and systems
shall be carried out to ensure that the features of the design have not altered or that the operational
performance has not deteriorated. Enclosures shall be checked since ingress of dirt and moisture
might affect creepage distances and clearances or lower the insulation level of certain parts of the
circuit. The integrity of the printed-circuit-board adherent insulating coating is to be visually
examined, because of its effect on creepages and clearances.

9.8.3.6.2 Some additional visual checks for broken tracks or loose conductors, cracked potting
materials, signs of overheating in the circuit, obvious modifications in the circuit or components,
bypassing of fuses, integrity of the sleeve of sleeved components, the state of the label of the
equipment, etc. may be conducted.

9.8.3.6.3 In general, the examination should be of a visual nature with no interruption to the supply.

9.8.4 Overhaul and repair

The overhaul or repair of intrinsically safe equipment shall not be attempted without an adequate
knowledge of those design aspects of the relevant items that are essential for intrinsic safety.

9.9 Battery bays

9.9.1 Battery charging and maintenance

WARNING 1: Always wear safety glasses and protective clothing when batteries are serviced.
Neutralize any acid spills immediately. If acid comes into contact with any part of the body, flush
immediately with running water and seek medical attention.

WARNING 2: Care shall be taken at all times to avoid electrical shock from the battery or charger.
The charger shall be turned off before the lead(s) to the battery are connected or disconnected.

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9.9.2 Jump-starting batteries

9.9.2.1 The procedure in 9.9.2.2 to 9.9.2.4 shall be followed when equipment with negative
grounded batteries is jump-started.

9.9.2.2 Connect one end of the jumper lead to the positive terminal of the dead battery and connect
the other end to the positive terminal of the booster battery.

9.9.2.3 Connect one end of the jumper lead to the negative terminal of the booster battery; then
connect the other end to the metal frame of the equipment being jump-started. Do this at an area
away from the battery and its associated fumes.

9.9.2.4 Once started, disconnect the jumper leads in the reverse order. First disconnect the lead
from the metal frame; then disconnect the jumper lead from the negative terminal of the booster
battery. Second, disconnect the jumper lead from the positive terminal of the booster battery, and
disconnect the lead from the positive terminal of the dead battery.

9.9.3 Traction batteries

9.9.3.1 Traction batteries are not intrinsically safe. Traction batteries and their installation are
certified as increased safety equipment.

9.9.3.2 Any short circuit between the battery terminals, between battery cells or between the
battery and any electrically conducting surfaces will ignite methane, if present. In addition an arcing
terminal connection is potentially dangerous. If any of the above occurs, the machine shall be taken
out of service and repaired immediately.

9.9.3.3 The practice of rebuilding terminal posts in hazardous areas by means of welding using the
battery as a power source, or by means of a flame, shall not be permitted.

9.9.4 Operating instructions

9.9.4.1 The following shall apply.

a) Do not operate in service if the temperature of the battery reaches 46 °C. High temperature is a
result of improper charger adjustments, high discharge rates, over-discharging, short cycling or
low water levels.

b) Keep plugs and receptacles clean and tight.

c) Remove vent caps only to check water level, temperature and specific gravity, or to add water.
Ensure that they are in place and tight at all times.

d) Do not weld, or grind or allow any sparks or flames near a battery. Do not allow tools or any other
metal to be laid on connectors of a battery.

e) Never add anything to the battery except distilled water.

f) Never add acid to a battery.

9.9.4.2 After a battery has been in operation for some time, dust mixed with spilled electrolyte
might collect on top of the battery cells. If this occurs, a number of low-resistance electrical paths
might form between the various cell terminals and the battery tray. Because the terminals are at
different potentials, stray currents might be formed that will tend to circulate across the battery top
and through the tray where insulation is defective or missing. These stray currents (commonly

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referred to as surface leakage) can cause the battery to overheat and might result in a fire. This
hazard, in the presence of the hydrogen and oxygen that are produced in a lead-acid battery while it
is being charged, could result in an explosion.

9.9.4.3 The surface leakage problem can be eliminated if batteries are properly maintained.
Legislation (see foreword) may be used to minimize the potential for surface leakage that could lead
to a fire or explosion hazard.

9.9.4.4 Title 30, Code of Federal Regulations (30 CFR), Part 7.44(h), requires the battery box and
cover to be either constructed from or lined with an insulating material. This insulating material
eliminates dangerous surface leakage currents between the cell terminals and the battery tray. The
mine environment, however, can be detrimental to the integrity of the insulation. Chipping and
abrasion of the insulation can occur in this environment, thus increasing the likelihood of surface
leakage currents. Routine inspection of the battery boxes, as required by 30 CFR, Part 75.512, shall
be performed and any noted damage shall be repaired.

9.9.5 Installation requirements for a battery-charging bay

Every approved battery-charging station shall be

a) constructed of non-flammable material;

b) provided with suitable and adequate fire extinguishing equipment;

c) equipped and operated in such a manner that the spillage of electrolyte is minimized;

d) provided with a water supply for emergency use;

e) provided with relevant warning notices or signs;

f) ventilated sufficiently to prevent the accumulation of explosive gasses or dust; and

g) equipped with a device to trip the incoming power supply in the case of ventilation failure.

9.9.6 Installing or removing batteries

9.9.6.1 The sequence in 9.9.6.2 to 9.9.6.3 shall be followed when negative grounded batteries are
installed or removed.

9.9.6.2 Shut off all lights and other electrical loads before battery maintenance is performed.

9.9.6.3 Always disconnect the negative connector before the positive terminal connector is
connected or removed.

9.9.6.4 If the wrench touches the grounded surface while the positive terminal is being tightened,
no arc will occur.

9.9.6.5 Similarly, when the negative terminal connector is being installed, no arc will occur since
the equipment frame is connected to the negative.

9.9.7 Maintenance of batteries

9.9.7.1 Maintenance procedures

9.9.7.1.1 The procedures in 9.9.7.1.2 to 9.9.7.1.3 shall be followed to ensure the safety of persons
who work with batteries.

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9.9.7.1.2 Before any maintenance or repair on a battery is performed, the battery compartment
shall be ventilated to dissipate any accumulation of gases. Batteries vent highly explosive gases
(hydrogen) that can be easily ignited if proper procedures are not exercized.

9.9.7.1.3 When a battery terminal becomes loose and could be twisted, the battery compartment
shall be ventilated for a few minutes before any of the terminals is tightened.

9.9.7.2 Watering

9.9.7.2.1 Generally, a certain amount of water loss is normal in all batteries and it shall be replaced
with distilled or demineralized water. The water level in each cell shall be maintained about 6 mm
below the bottom of the vent well. When being charged, the water levels shall be above the plates,
but care shall be exercized not to overfill before charging. Overfilling before charging can lead to
spill over of the electrolyte, which leads to tracking shorts and tray corrosion.

9.9.7.2.2 The steps in 9.9.7.2.3 to 9.9.7.2.4 shall be followed.

9.9.7.2.3 Add distilled water to 6 mm below the vent well only at the end of charging. Filling to this
level before charging will cause acid overflow.

9.9.7.2.4 Replace vent caps securely.

9.9.7.3 Cleaning batteries

9.9.7.3.1 Batteries shall be cleaned as given in the manufacturer’s recommendations.

9.9.7.3.2 Routine cleaning of batteries shall be done on an average of once a month to remove any
contaminants. More frequent cleaning might be needed if batteries are being operated in a dusty
environment or if electrolyte is spilled on top of the batteries. The batteries shall be cleaned using a
neutralizer or detergent solution made in accordance with the manufacturer’s recommendations.
The solution shall be applied with a non-metallic brush, so that it can be worked under the terminals
and inter-cell connectors to remove dirt and neutralize any excess acid. A low-pressure water hose
shall be used to rinse the battery with water until all traces of the solution and loose dirt are
removed.

9.9.7.4 Charging batteries

9.9.7.4.1 The procedures in 9.9.7.4.2 to 9.9.7.4.4 apply.

9.9.7.4.2 Exercise care when the battery charger is being connected. Connecting the wrong
polarity might cause a short circuit which could result in explosion of the battery.

9.9.7.4.3 Ensure that the battery charging circuit is de-energized before connections are made.
Once the connections have been made, the charging circuit can be turned on.

9.9.7.4.4 Ensure that charging parameters are in accordance with manufacturer’s specifications
and procedures.

9.10 Earthing systems

9.10.1 Electric storms

9.10.1.1 Electric storms, characterized by lightning discharges, cause the voltage at various places
on or below the surface of the ground to differ from true earth potential. As a result of these
voltages, stray currents flow through the ground on and below the surface. In addition, any
conducting parts will be at the potential of the ground with which they are in contact.

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9.10.1.2 Lightning discharges can result in the voltage of the ground at the main substation being
different from the voltage of the ground in other areas underground in a mine.

9.10.1.3 Lightning can result in voltage surges travelling along the overhead lines, feeding
distribution substations at a mine. To protect the electrical equipment at the substation, surge
diverters (lightning arresters or surge arresters) are connected between the incoming lines and the
electrical earth system.

9.10.1.4 An effective surge arrester should reduce the surge voltage crest and absorb the transient
energy in order to prevent reflection of the surge wave. The surge arrester is designed, through
non-linear resistors and air gaps, to limit the flow of power current. The characteristic of the resistor
is such that it permits reduced resistance to the flow of current as the current increases. This
characteristic allows a high current to flow without the voltage rising to a value that could damage
the system insulation. As soon as the surge wave has been discharged, the voltage across the
arrester drops and the current decreases. Under these conditions the resistor then reverts to an
insulator.

9.10.1.5 In addition, the earth path impedance might be substantially higher than the earth path
resistance due to kinks, coils and bends in the earth conductors. Thus, inductance in the earth path
is common, and the high rate of rise of a surge (wave front) results in high impedance even if the
inductance is relatively low. This means that the voltage rise of the electrical earth system is even
higher than when only the earth resistance is considered.

9.10.1.6 The rise in the electrical earth potential or changes to the potential of conducting parts can
result in elevated touch potentials, or can result in a discharge between the electrical earth and
conducting parts or the ground in the roof or floor underground. Such discharges can ignite
methane or coal dust. The flow of stray currents or the presence of stray voltages might also cause
premature detonation of explosives used for blasting.

9.10.2 Earthing of metalwork in mines

The objectives for ensuring low impedance earthing are given in (a) to (f).

a) The earthing and bonding normally required for power supplies underground in a colliery are
aimed at ensuring a secure, low-resistance metallic circuit from every point on the high- and low-
voltage power distribution network in the mine back to the earthing electrode of the power
authority’s supply substation on the surface.

b) Cables are protected with earthed sheaths, screens or armouring (or both) to prevent live
conductors being exposed in the event of damage to a cable, and to provide a good return path
for a fault current to supply transformer neutrals when insulation breakdown occurs. This
ensures the earth fault protection can then operate correctly to disconnect the power supply.

c) Earth fault currents are limited to minimize the rise in potential of earthed metal during the very
short period in which earth fault currents flow.

d) The fundamental aim of earthing is to ensure that all exposed metalwork is kept as close to the
electrical potential of the earth as possible at all times, to avoid potentially dangerous currents.

e) The primary method of negating the effects of stray potentials and currents is to ensure that all
extensive metalwork (for example, conveyor structures, rails, piping and cable sheaths, etc.) is
well earthed and bonded together. This is to ensure that all exposed metalwork is kept as close
as possible to the electrical potential of the general mass of earth at all times.

f) See figure 2 for an illustration of a typical layout of earthing

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Figure 2 — Typical layout for earthing

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9.10.3 Bonding of metalwork

9.10.3.1 Electrical systems are earthed by providing a connection to the general mass of earth. In
most cases this connection is made through a so-called “earth mat”.

However, even an extremely well-earthed system has a resistance of between the electrical earth
connection and the true earth potential of the general mass of earth. In addition it is virtually
impossible to provide an earthing system that has zero impedance to earth.

A lightning discharge on or near the overhead lines that supply the mine can give rise to a surge
wave (voltage) front travelling on the overhead line conductors.

Unless this surge can be prevented from entering the terminal equipment by the use of surge
arresters, severe damage to equipment will occur. The surge arresters discharge the surge through
the earthing system.

This voltage is the actual earth potential of the electrical system while the discharge is occurring.
Since the electrical earth voltage is now considerably higher than that of the true earth potential,
discharges are likely from the electrical earth system to any point at true earth potential, such as the
roof and floor underground. Other points that could be at true earth potential are steel pipes and
conveyor structures. These discharges could ignite methane and shall therefore be avoided. In
addition, persons in contact with the electrical earth system and true earth can receive a severe
shock.

If all equipment underground including the roof and the floor can be kept at the same potential
(equipotential), i.e. that of the electrical earth system, shocks and discharges underground cannot
occur.

NOTE If the resistivity of the roof or floor is tested, it is normally found to be too high in most cases. However,
since the equipment system does not have to carry current, the resistance of the connection should not
prevent an equipotential condition being achieved.

9.10.3.2 Normally all the precautions mentioned in 9.10.3.1 will be implemented, but it is commonly
found that certain additional safety measures, which are important to ordinary electrical safety and
in connection with protection against lightning and other stray current effects, are neglected. These
include the bonding together of adjacent metalwork, such as conveyor drive motor frames with
conveyor steelwork (sometimes insulated from one another due to the use of non-conductive shaft
coupling elements and separate mounting of motors on concrete pedestals). The head of each
conveyor structure shall also be electrically bonded to the steel structure of the conveyor onto which
it discharges.

Bolting of steel structure elements provides a sufficiently continuous bond for this purpose. In the
absence of such bolted connections a suitable electrical bond shall be installed.

9.10.4 Distribution substation earthing

9.10.4.1 Objectives of transformer neutral point earthing

The objectives of earthing the neutral point of the transformer are the following:

a) to stabilize the voltages between phase and earth;

b) to limit transient overvoltages in order to minimize the arc energy and subsequent damage; and

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c) the value of the earth connection shall be such as to allow sufficient current to flow, enabling
operation of the protective devices; these devices are to clear the fault condition that isolates the
safety equipment of the circuit.

9.10.4.2 Factors that affect distribution substation earthing

9.10.4.2.1 The resistivity of the soil is the prime factor that determines the effectiveness of the
connection between the system earth and the general mass of earth. Good earthing practice
requires low soil resistivity.

9.10.4.2.2 Resistivity of the soil could be affected by the factors in (a) to (d).

a) Soil type

The structure and composition of soil vary greatly from location to location. Soils can have the
following compositions: clay, loam, rock, sand, shale, silt, stone, etc. The soil structure can vary
from a homogeneous structure to a mixture depending on the location. The substation earth
electrode system shall be located in the lower soil strata where it is subject to minimal moisture
loss under normal climatic conditions.

b) Climatic conditions

The location of the substation will dictate the earthing requirements in order to obtain a low
resistance earth condition. An arid region will normally have a high soil resistivity compared to a
high rainfall area that will conversely have a low soil resistivity. Drought will have the effect of
increasing the normal soil resistivity in a good rainfall location.

The primary effects of seasonal climatic changes are the temperature and moisture effects on
the condition of the soil resistivity. During winter the effect of the frost or freezing of the soil
layers will lead to an increase in the soil resistivity. These conditions will require earth mat rods
to be driven to greater depths.

c) Chemical composition

The nature and composition of chemical compounds in the soil structure have an effect on the
conductivity of the soil. The presence of salts in the soil has the effect of decreasing the soil
resistivity. Depending on the nature of the soil resistivity it might be difficult to obtain acceptable
values of substation earth path resistance. If this is the case, then use is to be made of specialist
designers in order to optimize system-earthing design.

d) Colliery earthing practice

The main distribution substation that feeds an underground mine shall have an earth system
installed to which the neutral point of the supply transformer is connected. The distribution
substation can be fed from the supply authority's reticulation network or from part of the mine
reticulation system.

The earthing philosophy adopted by the majority of South African collieries is to restrict the earth
fault current on medium-voltage installations to 300 A. The restriction is achieved by the
installation of a neutral earthing resistor (NER) or neutral earthing compensator (NEC) between
the transformer neutral and the substation earth.

Older installations are effectively earthed with the transformer neutral connected solidly to the
substation earth. This type of installation is potentially hazardous, as there is minimal restriction
on the magnitude of earth fault current that could vary between 2 000 A to 10 000 A.

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9.10.5 Installation

9.10.5.1 Earthing precautions against lightning

9.10.5.1.1 A primary protective measure, which can be taken against lightning, is to ensure that all
metal conductors that enter an underground mine are well earthed at the surface. Earthing requires
attention at the collar for vertical shafts and at the point where incline shafts and adits reach ground
level.

9.10.5.1.2 In addition, connections within the underground workings, such as those of the
armouring or sheaths (or both) of power and telephone cables and pipes, which pass through
boreholes, and the steel casings of the boreholes themselves, shall be well earthed at the surface
and underground where the casings should be bonded to adjacent metalwork close to their points of
entry to the workings.

9.10.5.1.3 For an effective design of an earthing system, a soil resistivity survey shall be done in
the vicinity of the mine workings. If the mine installation is situated in an area with a high incidence
of lightning activity, then specialists on earthing and surge protection should be consulted since
each geological area has its own particular constraints.

9.10.5.1.4 As a general principle, at the collar or portal of a shaft, it is recommended that a copper
ring conductor around the shaft opening be buried in the ground (at a minimum depth of 0,5 m) and
connected at several points to the shaft steelwork and the head frame, to the incline conveyor
structure, or to fan housing, as the case might be.

9.10.5.1.5 The ring conductor might also usefully encircle the stockpile where a shaft conveyor
delivers direct onto a stockpile.

9.10.5.1.6 In order to obtain satisfactorily low earthing impedance it might be necessary to improve
the earthing electrode system by the addition of radial buried conductors and vertical driven rods (or
both).

9.10.5.1.7 At the entrance to the shaft or adit, all pipes, rails, cables, conveyor structures, handrails
and other continuous metalwork in the shaft shall be bonded together and connected to the earthing
system.

9.10.5.1.8 To reduce the inductance of the earth path at the main substation, all earth conductors
shall be laid or run in as straight a position as possible. Coils in the conductor, bends or kinks
increase the impedance of the earth conductors.

9.10.5.2 Power supply equipment: method of earthing

9.10.5.2.1 Earth fault currents are limited in magnitude to minimize the rise of potential of earthed
metal during the periods for which earth fault currents flow.

9.10.5.2.2 Impedance earthing of the system neutral is required to limit earth faults to an
acceptable pre-determined level.

9.10.5.2.3 MV impedance earthing is done through a NEC or NER which is dependant on the
vector group and is normally limited to 300 A.

9.10.5.2.4 Low and medium-voltage system earthing is typically done through a current-limiting
resistor. (A neutral earthing resistor monitor is installed in order to monitor the integrity of the
resistor.)

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9.10.5.2.5 Solid earthing is also found on collieries.

9.10.5.2.6 Earth loop resistance and bonding can be continuously monitored by means of pilot
circuit protection.

9.10.5.2.7 Earth bonding or cross-bonding of individual equipment is not monitored and does not
form part of a pilot earth loop system.

NOTE LV systems use pilot wire protection and MV reticulation systems use earth continuity monitors (ECM).

9.10.5.2.8 The main reason for continuous earth path monitoring on MV systems through ECMs is
to ensure that a continuous earth return path is present so that earth fault protection can operate.

9.10.5.2.9 The earthing and bonding normally required by legislation (see foreword) for electric
power supplies underground in a colliery is aimed at the results given in (a) and (b).

a) To ensure a secure, low-resistance metallic circuit from every point on the medium and low-
voltage power distribution network in the mine back to the earthing electrode of the incoming
power supply substation on the surface.

b) To ensure that cables are protected by earthed screens or armouring (or both) to prevent live
conductors from being exposed in the event of damage to a cable, and to provide a good return
path in the case of an earth fault current. A separate earth conductor shall be installed from the
main substation earth to the underground workings.

9.10.5.3 Cross-bonding of electrical and other metalwork

9.10.5.3.1 Conveyor structures and steel pipes can be kept at the potential of the electrical earth
system by connecting them to the electrical earth at regular points.

9.10.5.3.2 Care shall be taken to connect both sides of any such structure or pipe to each other
where they do not make contact with each other or in the presence of an electrically insulating
section (transfer points on conveyors can be such points of no contact. Sections of plastic pipe in an
otherwise steel pipeline are insulating sections).

9.10.5.3.3 Bare copper conductors shall be used for earth connections. The conductor's
cross-sectional area shall be 70 mm2 or greater so as to provide adequate mechanical strength.

9.10.5.3.4 The connections to pipes and structures shall be made to clean, corrosion-free and
paint-free sections of metal. The connections shall be protected against corrosion by coating the
connection with grease after completion. Use of exothermic welding methods to make an earth
connection shall be avoided underground.

9.10.5.3.5 In principle, all continuous metallic service elements (such as cable sheaths and
armouring, pipes, conveyor structures and rails which follow common parallel routes) shall be
cross-bonded at regular intervals not exceeding 600 m. Ordinarily such cross-bonding will be done
at MV cable joint areas, MV cable couplers and transformer installation points. Cross-bonding shall
also include low-voltage control cabling, i.e. signalling, telemetry, telephone, and lighting cable
armouring where present.

9.10.5.3.6 Where plastic type luminaires are used, the earth conductors shall be carried through
the luminaire connector to the loop cable to the next fitting.

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9.10.5.4 Bonding conductors

Bonding conductors should be of stranded copper or galvanized steel wire of cross-sectional area
70 mm2 or larger, in order to be of sufficient mechanical strength to ensure reliability in service.
Where cross-bonding problems are experienced, for example, to control cable armouring, it is
recommended that suitable earthing cable clamps and lugs be used in a bolted connection.

9.10.5.5 Connection of metallic parts to underground earthing electrodes

9.10.5.5.1 Providing connections to the roof and floor to keep these at the electrical earth system
potential is more complex than the earthing of structures and pipes.

9.10.5.5.2 Connecting the electrical earth to the roof and floor at every cable coupler (for example,
300 m) across the coupler and at every transition point, will provide an acceptable equipotential
system.

9.10.5.5.3 Roof bolts used for suspending cables, or catenaries on which cables are suspended,
shall be used to create an equipotential system.

9.10.5.5.4 If a catenary is used to support cables, and the catenary is connected to the cable
armouring, the catenary can act as a means to provide equipotential roof conditions. However, the
catenary shall be installed using uninsulated roof bolts. Insulated roof bolts shall not be used.

9.10.5.5.5 The earth point of each underground transformer shall be connected to the roof and floor
using uninsulated roof bolts.

9.10.5.5.6 The transformer earth shall also be connected to any pipes or conveyor structures in the
vicinity.

9.10.5.5.7 Roof bolts using the “clamshell” type of fixing, similar to rawl bolts, are uninsulated. In
addition, only electrically conducting resin shall be used for roof bolts used for earthing purposes.
The roof bolts so used shall be of a type that has a good earth connection with the surrounding
strata. For this purpose the use of roof bolts that are insulated with epoxy or other resin shall be
avoided.

9.10.5.5.8 Transient potential differences can develop, for example, between a conveyor structure,
or mobile electrically powered machines, and the roof, face and floor of underground workings. This
might present the risk of an electric shock to people during thunderstorms, and also the risk of
discharges across charged faces to nearby "earthed" metal objects such as coal drills which might
lead to premature detonation of explosives.

9.10.5.5.9 Such risks arise particularly where underground workings are extensive and the
electrical substation’s earth on the surface might be 2 km to 5 km away from a face area. The
general aim is to minimize these transient differences in potential and this might be achieved by
providing a local electrical connection between the general mass of the earth in the working area
and the nearby continuous metallic service elements.

9.10.5.5.10 Good earthing practice may be achieved by earthing the face end of conveyor
structures to nearby roof bolts connected together in groups of at least three roof bolts and
repeating this at intervals of not exceeding 200 m as the working face advances.

9.10.5.5.11 Despite their high individual electrical resistances to earth, substantial improvement of
conditions is possible by the means in 9.10.5.5.10. Unless this is already a cross-bonding position
as in 9.10.5.3, the flameproof switchgear at the face shall additionally be bonded direct to the
conveyor.

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9.10.6 Inspection and maintenance

9.10.6.1 Inspection

To ensure operation of an earth leakage system under a fault condition, the following shall be
inspected:

a) the mechanical integrity of the earthing system shall be examined for continuity and loose
connections; and

b) the earth conductor current-carrying capacity shall be rated for the system.

9.10.6.2 Substation earth path resistance

9.10.6.2.1 The earth resistance of the substation earth electrode system at each area is unique,
therefore, the measurements and tests in (a) and (b) shall be done.

a) Measurements shall be taken before the commissioning of the substation, in order to confirm
that the design of the substation earth electrode system has been optimized. This reading shall
be kept in the substation logbook.

b) Annual tests shall be carried out in order to ensure that the value of the earth path resistance is
within acceptable limits.

9.10.6.2.2 Representative measurements shall be taken during the dry season in order to obtain a
conservative substation earth resistance value.

NOTE The most common method of measuring the resistance between the earth mat and rod is by means of
a 3 or 4 terminal earth test instrument.

9.10.6.3 Earthing and bonding requirements on-board mobile machinery

9.10.6.3.1 Where enclosures are part of a mobile machine and, for operational reasons, external
earthing or bonding conductors are not practical, bonding shall be done through the frame of the
machine to which the unit is fitted. For this reason no external bonding facilities are considered
necessary, and provided that the integrity of the low resistance of the earth path is maintained, the
main incoming earth to a mobile machine shall be electrically bonded to the machine frame by a
cable or bus system of suitable cross-sectional area.

9.10.6.3.2 Internal panels, doors and swing panels inside flameproof enclosures, on which
electrical equipment is mounted, shall be bonded to the main enclosure by means of a conductor of
suitable size. Cable screens shall be bonded to the enclosure or the motor frame (or both), close to
the point of entry to the enclosure. Fasteners used for bonding purposes shall be adequately
protected against corrosion taking into consideration earth fault currents, resistance to earth and
mechanical strength.

9.10.6.3.3 Sub-assemblies on machines that are not electrically continuous with the main body of
the machine, i.e. are joined through a hinge or pivot mechanism, should be electrically bonded to
the main body by means of a suitable earthing conductor.

9.10.6.3.4 The metal frame and core of on-board power transformers shall be bonded to the frame
of the electrical enclosure by means of an electrical conductor of suitable cross-sectional area.

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9.11 Communication equipment

9.11.1 General

9.11.1.1 With the increase in the demand for more information from equipment, various
developments have taken place to improve on the effectiveness of obtaining information from all
types of mining equipment.

9.11.1.2 Due to the nature of the information required, high-speed networks, state of the art
technology and bus communication systems are installed in mines. These systems cover a wide
range of applications, i.e. voice, video, control data, data monitoring and data logging.

9.11.1.3 Typical communication systems that can be encountered on mines today are

a) local area networks,

b) wide area networks,

c) ethernet systems,

d) serial open bus networks,

e) PLC and SCADA control systems,

f) high-speed modems,

g) radio-frequency networks,

h) open backbone systems,

i) optical fibre networks,

j) telephone or voice (or both) communication systems,

k) environmental systems, and

l) complex multiplexer transmission systems.

These systems are installed on the surface and throughout underground areas, and shall be
properly designed as they are interconnected between hazardous and non-hazardous areas.

9.11.2 Installation

9.11.2.1 Communication system design shall address the critical issues given in (a) to (j).

a) Surge protection to prevent any external power surge from entering the communication system
coupling of the frequency component of data transmission.

b) Cross-bonding of cable joints.

c) System earthed to “clean” (separate) instrumentation earth system that is isolated from power
earth systems. These systems will normally be earthed only at the surface to limit earth current
loops that produce noise on the communication system.

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d) Intrinsically safe circuits “ia” for equipment installed in hazardous areas if the equipment needs to
remain energized.

e) Where optical fibres are used, light source power emission shall comply with statutory
regulations (see foreword).

f) Radio-frequency power sources shall comply with statutory regulations (see foreword).

g) Data separation of control and SCADA data. This is extremely important for system integrity and
is achieved through switches, routers, bridges, gateways and hubs.

h) Cable selection criteria for hazardous areas (see 9.6.6).

i) Electromechanical screening of electronic equipment that prevents radio-frequency emissions or

data corruptions.

j) Earthing of cables and equipment to prevent electrostatic charging due to capacitance.

9.11.2.2 Reticulation drawings should be kept up to date and made available.

9.11.3 Inspection

9.11.3.1 Routine inspection on equipment should be done on a regular basis as defined in a mine-
specific code of practice. These inspections should be a visual or simulation test (or both).

9.11.3.2 Visual inspections should cover the following:

a) dust contamination;

b) moisture contamination;

c) physical damage;

d) sealing integrity;

e) Ex protection;

f) marking labels intact;

g) earthing in place;

h) cross-bonding in place;

i) condition of booster power supplies; and

j) recording of diagnostic readout (where installed).

9.11.3.3 The simulation of controlled conditions and then recording the results of equipment with
defined test parameters can only determine the condition of certain equipment. These procedures
are normally conducted in hazardous areas and shall be properly defined in the mine-specific code
of practice to ensure compliance with pre-test conditions for live testing.

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9.11.4 Maintenance

9.11.4.1 Qualified repairers should carry out maintenance of intrinsically safe equipment. Where
calibration of equipment is required, guidelines should be in place to ensure compliance with
specified operation settings.

9.11.4.2 Cleaning of equipment is normally the basic maintenance requirement. This can be
achieved by

a) immersing the equipment in a cleaning solution, and

b) removing dust build-up (contamination).

9.11.4.3 Solutions used to remove contamination from equipment normally have a high evaporation
rate made possible by low latent heat liquids (such as alcohol). Gasses released through the
evaporation process are not healthy and these solutions should be used only in well-ventilated
areas.

9.11.4.4 Use of compressed air to remove dust should be done in controlled environmental areas.
The mine should ensure that the procedure for using compressed air is stipulated in a code of
practice.

9.11.4.5 Replacement of fasteners and seals shall be done in accordance with the supplier’s
maintenance procedures.

9.11.4.6 Repairs to cables and optical fibres in hazardous areas shall be done in accordance with
OEM specifications.

9.11.4.7 Only competent personnel shall conduct tests or calibration of communication equipment.

9.12 Hand-held portable equipment

9.12.1 The power supply of equipment supplied from a single-phase supply of not exceeding
250 V a.c. and designed to be carried and held by hand whilst in use, shall

a) be earthed through a current-limiting device to limit touch potentials to a safe value,

b) be automatically disconnected in the case of an earth fault,

c) be automatically disconnected in the case of an overload,

d) be automatically disconnected in the case of a short circuit, and

e) have a fail-safe continuous monitoring system to monitor the integrity of earth and pilot
conductors in the supply cable.

9.12.2 Only non-latching switches shall be permitted to start a machine.

9.13 Moveable electrical equipment

9.13.1 General

Equipment that is designed to be moved, when required, shall be isolated from all sources of
electrical supply whilst being moved. The equipment shall be constructed with adequate mechanical

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strength to support itself without damage to the electrical components and connections whilst in
transit. It shall be suitable for the rough terrain found in underground mines.

9.13.2 Pumps

9.13.2.1 General

9.13.2.1.1 Pumps are generally installed where conditions are wet, access is restricted and
environmental conditions pose hazards. Therefore the minimum safety critical devices shall be
checked to ensure that they are operational and functional. A risk assessment for each pump
installation shall be conducted before being put into service. All the required safety instructions shall
be recorded and filed for future reference. Pump duty shall be calculated for each pump installation
to prevent overloading of equipment due to the under design of pump systems.

9.13.2.1.2 Each mine shall have a code of practice for the following:

a) the installation of pumps;

b) scheduled inspections;

c) scheduled maintenance programmes; and

d) operating procedures.

9.13.2.2 Installation

Due to the arduous environmental conditions, the minimum safety protection and design
considerations given in (a) to (j) shall be adhered to.

a) Earth leakage protection.

b) An earth leakage lockout system that prevents a pump or pump station from being energized
with an earth fault condition. In the case of a secondary contactor at the pump station that
switches power to the pump motor, the risk assessment should determine the need for an earth
leakage lockout circuit between the secondary contactor and the pump motor.

c) An intrinsically safe pilot system to continuously monitor the earth continuity, between
switchgear, the pump starter panel and the pump motor, i.e. a remote diode should be located at
the motor.

d) The correct cable size selection to prevent cable overloading, severe voltage drop and
undetected short-circuit conditions due to high cable impedances. Only individual or collective
earth screened power cables shall supply the pump.

e) Overload and short-circuit protection.

f) Protection to prevent the pump from running dry, and overheating.

g) Protection to protect the pump against overtemperatures (optional).

h) The pump system shall include the following:

1) power supply cables to pumps that are suspended to prevent damage;

2) pump starters of robust design with facilities for lockout purposes;

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3) pump starter panels and associated switchgear rated to withstand the fault current under
short-circuit conditions;

4) Where practicable, indication lights and controls on the pump starter panel, for example:

• an "isolate elsewhere" label;

• “on/off” indication;

• applicable fault indication lights;

• start button;

• stop button;

• pilot healthy;

5) an installation that is floor mounted on fabricated skids, or bolted on a frame, or of the

submersible type;

6) switchgear that supplies pumps with power, clearly marked and all protection settings
displayed.

i) Precautions shall be taken to prevent inadvertent or accidental connection of pumps to

switchgear not rated for the duty.

j) Where pumps are installed in roadways, the area shall be clearly marked and barricaded, to
prevent machines from driving over pumps.

9.13.2.3 Inspection

The installed equipment shall be inspected as detailed in (a) to (g).

a) Ensure that the frequency of the regular inspections is in accordance with mine-specific
procedures.

b) Ensure that the switchgear protection settings are in accordance with the pump rating.

c) Ensure that all inspection covers, doors, plug and socket fastening bolts are in position, tight and
all flameproof gaps are clean, free from corrosion and dust, and comply with SANS 60079-0 and
SANS 60079-1.

d) Ensure that the earth system continuity is compliant.

e) Ensure that the conditions of the cables are such that the cables are free from damage and
properly suspended.

f) Carry out any other inspection advised by the equipment manufacturer.

g) Ensure that the switchgear is free from dust and water build-up (contamination).

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9.13.2.4 Maintenance

The equipment shall be maintained as detailed in (a) to (g).

a) Ensure that maintenance intervals are in accordance with approved mine-specific procedures.

b) Carry out all inspections described under scheduled inspections.

c) Inspect all LV connections for tightness and signs of damage, tracking or overheating.

d) Perform the insulation test on the power supply cable and the pump motor. Take care not to
damage the pilot diode installed in the motor.

e) Ensure that the earth continuity is in place between the switchgear, starter panel and pump
motor.

f) Carry out any maintenance and tests advised by the equipment manufacturer.

g) Where possible, confirm the duty point of the pump and record the current during tests.

9.13.3 Moveable underground substations

9.13.3.1 General

The preparation of a code of practice for permanent and moveable underground substations in coal
mines shall be as described in 9.13.3.2 to 9.13.3.5.

9.13.3.2 Location for moveable underground substations

A moveable underground substation shall be located in the intake airway and positioned in
accordance with the escape strategy of the mine-specific code of practice.

9.13.3.3 Single-line diagram

A single-line diagram of the MV supply reticulation shall be displayed in every moveable

underground substation. The position of the specific substation shall be clearly indicated on this
single-line diagram.

9.13.3.4 Construction

The following points shall be taken into account.

a) Equipment drawings – Schematic drawings of electrical equipment shall be available.

b) Unauthorized entrance into substations – Substations shall be barricaded to restrict the

entrance of unauthorized persons.

c) Containing and drainage of oil – Provision shall be made to safely contain oil that drains from
or splashes from oil-filled equipment and to reduce the potential fire hazard to a minimum.

d) Lighting – Lighting shall be provided in accordance with the mine-specific code of practice.

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9.13.3.5 Fire protection

The following points shall be taken into account.

a) Fire risk assessment – An assessment of the fire risk associated with a moveable substation
shall be carried out and the necessary preventative action shall be implemented to minimize or
remove such fire risk.

b) Fire extinguishers – Fire extinguishers shall be provided as required by legislation (see

foreword).

c) Protection of combustible materials and cables – All combustible materials, including cables,
shall be suitably protected to prevent propagation of fire.

9.13.3.6 Electrical protection

9.13.3.6.1 Electrical protection and service information

Appropriate records of substation fault levels, protection settings, commissioning and maintenance
details shall be kept. Protection settings shall also be displayed in substations. It is recommended
that the following information be recorded:

a) the fault current at the terminals of the main incoming MV circuit-breaker;

b) the date when the calculation was made;

c) the name of the authorized engineer responsible for the calculation;

d) the signature of the engineer responsible for the calculation;

e) the protection relay settings for short circuit, overcurrent and earth fault currents;

f) the date and type of the last service;

g) the name of the person who was responsible for the last service;

h) the signature of the person responsible for the last service; and

i) fuse ratings for fused isolators.

9.13.3.6.2 Procedures

Procedures shall be provided in the mine-specific code of practice for underground substations for:

a) planned maintenance;

b) updating of relay settings;

c) operation of electrical equipment;

d) lock-out, earthing and permit to work;

e) earthing practices to ensure that the substation equipment is effectively earthed; and

f) log books to record events.

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9.13.3.6.3 Electrical protection and rating of equipment

9.13.3.6.3.1 Electrical equipment (transformers, cables, switchgear, MV and LV panels) shall be

suitably rated, designed and protected against short circuit, overcurrent and earth fault currents.
The application of back-up protection is recommended.

9.13.3.6.3.2 The protection requirements of the substation that feeds the equipment are

a) short-circuit protection,

b) overcurrent protection, and

c) earth fault protection,

set to protect the downstream load and cable with discrimination.

9.13.3.7 Physical protection

9.13.3.7.1 General

Personnel protective equipment (PPE) shall be made available.

9.13.3.7.2 Notices

Notices shall be displayed in conspicuous positions indicating

a) substation designation, equipment labelling, ring feeds, and voltage level, and

b) electrical warnings, unauthorized entry, procedures in the case of fire and first-aid treatment for
electric shock.

9.13.3.7.3 Lock-out facilities

All electrical switchgear shall be provided with lock-out facilities.

9.13.3.7.4 Flash protection when switchgear is operated

All switchgear shall be protected by either a covering door or a faceplate when being operated.

9.13.3.7.5 Substation equipment

Suitable equipment to protect the operator from switching hazards shall be available. Remote
operation of MV switchgear is recommended. Equipment required for the safe earthing, phasing
and voltage detection of MV switchgear shall be available.

9.13.4 Compressors

9.13.4.1 General

9.13.4.1.1 A risk assessment for each compressor installation shall be conducted before it is put
into service. All the required safety instructions shall be recorded and filed for future reference.

9.13.4.1.2 Compressor duty shall be calculated for each installation to prevent overloading during
normal operation.

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9.13.4.1.3 Each mine shall have a code of practice for the following:

a) the installation of compressors;

b) inspections; and

c) a maintenance programme for compressors.

9.13.4.2 Installation

9.13.4.2.1 The following design and minimum safety critical protection shall be adhered to.

a) Power supply cables to compressors shall be suspended to prevent damage.

b) Switchgear equipment shall be able to withstand the fault current under short-circuit conditions.

c) Switchgear that supplies compressors with power shall be clearly marked. All protection settings
shall be displayed.

d) Where compressors are installed in roadways the area shall be clearly marked and barricaded to
prevent machines from damaging compressors.

9.13.4.2.2 Due to the arduous environmental conditions, the minimum safety protection and design
considerations in (a) to (g) shall be adhered to

a) Earth leakage protection.

b) An earth leakage lock-out system that prevents a compressor from being energized with an earth
fault condition.

c) An intrinsically safe pilot system to continuously monitor the earth continuity.

d) The correct cable size selection to prevent cable overloading, severe voltage drop and
undetected short-circuit conditions due to high cable impedances.

e) Overload and short-circuit protection.

f) Compressor overtemperature protection (optional).

g) Only individual and overall earth screening power cables to supply the compressor with power
shall be used; this limits the fault level to the earth fault level that is normally restricted to a
maximum of 2,5 A.

9.13.4.3 Inspection

The installed equipment shall be inspected as detailed in (a) to (g).

a) Ensure that the frequency of regular inspections is in accordance with mine-specific procedures.

b) Ensure that switchgear protection settings are in accordance with the compressor rating.

c) Ensure that all inspection covers, doors, plug and socket fastening bolts are in position, tight and
all flameproof gaps are clean, free from corrosion and dust, and comply with SANS 60079-1.

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d) Ensure that earth continuity is in place.

e) Ensure that cables are free from damage and are properly suspended.

f) Carry out any other inspections advised by the equipment manufacturer.

g) Ensure that the switchgear is free from dust and water build-up.

9.13.4.4 Maintenance

The equipment shall be maintained as detailed in (a) to (g).

a) Ensure that maintenance intervals are in accordance with mine-specific procedures.

b) Carry out all inspections described under scheduled inspections.

c) Inspect all LV connections for signs of damage and tracking.

d) Perform the insulation test on the power supply cable and the compressor motor. Take care not
to damage the pilot diode installed in the motor.

e) Ensure that earth cross-bonding is in place between the switchgear and the compressor motor.

f) Carry out any maintenance and tests advised by the equipment manufacturer.

g) Where possible, confirm the duty point of the compressor and record the current during tests.

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Annex A
(normative)

Live testing in hazardous areas

A.1 Energizing of open or partly dismantled explosion-protected equipment in a hazardous area

shall be kept to an absolute minimum. Wherever possible, self-propelled mobile machines shall be
removed from the hazardous area before any explosion-protected equipment installed or that forms
part of such machine is energized.

A.2 Testing on live explosion-protected equipment in a hazardous area shall only be carried out
by suitably qualified competent persons.

A.3 The person that wishes to energize explosion-protected equipment in a hazardous area for
testing purposes shall not commence with such work until he is in possession of a written work
permit authorized by the engineer.

A.4 An approved continuous monitoring flammable gas measuring instrument shall be used at all
times while electrical testing is in progress and such instrument shall be under the care and control
of the holder of a gas-testing certificate, in order to ensure that no flammable gas is present in the
atmosphere that surrounds the explosion-protected equipment. Tests for flammable gas shall be
carried out at frequent intervals to ensure that danger is not likely to occur while equipment is live in
a partly open or dismantled condition.

A.5 During live testing of explosion-protected equipment the velocity of the air that flows over the
equipment shall be not less than 1 m/s or as specified in the mine-specific ventilation code of
practice.

A.6 No wiring shall be connected or disconnected while the explosion-protected equipment is

energized. Care shall be taken not to short-circuit any phase-to-phase or phase-to-earth potentials
with the instrument test leads. Due note shall be taken of cable and capacitors that could hold
charge after the power has been disconnected.

A.7 Every such operation shall be recorded in a book to be provided by the manager and shall at
all times be available for inspection by an interested party.

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Annex B
(normative)

Insulation testing of cables in hazardous areas

B.1 General
All insulation testers, whether or not the tester output complies with the requirements for an
intrinsically safe supply, are capable of charging a cable to a level at which any spark caused during
the testing or discharging of the cable is sufficient to ignite methane or coal dust.

If the insulation tester output is classified as being intrinsically safe and the length of the cable is
less than 100 m, the charge on the cable is usually not capable of igniting methane.

Most cables in or feeding into a hazardous area are invariably longer than 100 m. When such
cables are to be insulation tested, the mine-specific procedures shall be followed.

B.2 Procedure

B.2.1 The procedures in B.2.2 to B.2.13 shall be followed for the insulation testing of cables that
carry voltages of up to 1 000 V.

B.2.2 Ensure that the cable and any associated circuits that could feed power into the cable, are
de-energized and locked out in accordance with an approved lock-out procedure.

B.2.3 Ensure that insulation tests are only carried out by an authorized person who is competent to
carry out the test and who recognizes the associated risks involved.

B.2.4 Before the test, examine the entire length of the cable that is to be tested for signs of
physical damage. Where such an examination is impossible, follow the procedure in B.2.10.

B.2.5 If any physical damage likely to have resulted in damage to the cable core insulation is
detected, remove the cable and send it for repair.

B.2.6 While the cable is being examined as in B.2.4, carry out tests along the entire length of the
cable to ensure that methane concentrations exceeding 1,0 % do not exist at any point in the
vicinity of the cable.

B.2.7 Examine the end remote from the point at which the insulation test is to be carried out to
determine whether a discharge is likely to occur at this end of the cable while the test is being
carried out.

B.2.8 If the remote end consists of exposed cable cores, separate these and, if necessary, restrain
them to prevent a discharge from occurring at the cores during the test.

B.2.9 If the remote end is fitted with a cable coupler, which shows any sign of damage, replace the
cable rather than subject it to insulation testing.

B.2.10 Ensure that the test meter leads are mechanically sound and the connections between the
test meter and the cable are securely made so that they do not separate while the test is being
undertaken.

SANS 10086-2:2013
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B.2.11 Once the test has been completed, electrically discharge the length of cable that has been
tested.

NOTE 1 With certain meters, an insulation resistance reading can only be obtained by discharging the cable
through the meter.

NOTE 2 In the case of insulation testers that do not have this facility, leave the insulation tester connected to
the cable until the cable is discharged.

NOTE 3 Insulation testers with an analogue display (meters with a pointer and scale) will discharge
reasonably quickly if left connected to the cable. The state of the charge on the cable can be seen on the
meter.

NOTE 4 Insulation testers with digital meters take longer to discharge and the state of charge cannot be read
off the display. (The rate of discharge can be tested using a voltmeter to measure the voltage when a cable in
good condition has been insulation tested. The time taken for the insulation tester to discharge to
approximately 50 V can be used as the discharge time required. The time for discharge is the time allowed
when that meter is used.)

B.2.12 Carry out a further test to verify that the concentration of methane in the vicinity of the test
area is less than 1,0 %, if the cable is discharged by shorting the cores to earth. Do not use this
method of discharging the cable on a cable that has not been allowed to discharge through the
insulation tester.

B.2.13 Should the cable enter a sealed area or should the route of the cable be obstructed for any
other reason it will not be possible to follow the route of the cable for inspection purposes. In that
event, before the insulation resistance of the cable is measured, the following shall be considered:

a) whether the sealed section is likely to contain mixtures of explosive gas;

b) whether the cable might have been extensively damaged by a fall of the roof within the section
that cannot be examined and thus cannot be repaired; and

c) whether to by-pass the section of cable that enters a sealed area or an area where the cable
cannot be examined.

B.3 Procedure for insulation testing 3,3 kV, 6,6 kV and 11 kV cables
In addition to the measures stated in B.2, due note shall be taken of the manufacturer's
recommendations and procedures.

NOTE Touching a cable charged with a high-voltage insulation tester can result in a severe and potentially
lethal shock.

SANS 10086-2:2013
Edition 2

Annex C
(informative)

Main parameters that affect the frequency of inspections

The main factors that affect the deterioration of equipment and the frequency of inspections are:

a) the manufacturer's or supplier's recommendations;

b) the risk assessment on application equipment;

c) the history of incidences;

d) the presence of one or more of the following conditions:

1) susceptibility to corrosion;

2) exposure to chemicals or solvents; and

3) the likelihood of the accumulation of dust and dirt;

e) the likelihood of water ingress;

f) exposure to excessive ambient temperatures;

g) the risk of mechanical damage;

h) exposure to undue vibration;

i) training and experience of personnel;

j) the likelihood of unauthorized modifications or adjustments; and

k) the likelihood of inappropriate maintenance, for example, not in accordance with the
manufacturer's recommendations.

SANS 10086-2:2013
Edition 2

Annex D
(informative)

The control of Ex equipment

D.1 General
The information in D.2 to D.9 is typically required in a code of practice for the selection, purchase,
repair, modification, inspection, maintenance and record keeping of Ex equipment.

D.2 The selection and purchase of Ex equipment

The examples given in (a) to (e) are typical of the information required for the selection and
purchase of Ex equipment.

a) Which companies and products are approved by the mine to supply Ex equipment to the mine
and specifically what type of Ex equipment is supplied?

b) What are the mine's selection and purchasing procedures?

c) The necessary mine approvals and signatories.

d) In accordance with which standards and specifications is the equipment to be manufactured?

e) The type of inspection of equipment required before delivery and upon receipt at the mine.

NOTE 1 See SANS 10108.

NOTE 2 A risk assessment by the manufacturer is required on the equipment to be supplied.

D.3 The repair of Ex equipment

The examples given in (a) to (e) are typical of the information required for the repair of Ex
equipment.

a) Which companies are approved by the mine to repair Ex equipment for the mine and specifically
what type of Ex equipment?

b) What are the mine's purchasing procedures for the repair of equipment?

c) The necessary mine approvals and signatories.

d) In accordance with which standards and specifications is the equipment to be repaired?

e) The type of inspection of equipment required before delivery and upon receipt at the mine.

D.4 The modification of Ex equipment

The examples given in (a) to (e) are typical of the information required for the modification of Ex
equipment.

a) Which companies are approved by the mine to modify Ex equipment for the mine and specifically
what type of Ex equipment?

b) What are the mine's purchasing procedures for the modification of Ex equipment?

SANS 10086-2:2013
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c) The necessary mine approvals and signatories.

d) In accordance with which standards and specifications is the equipment to be modified?

e) The type of inspection of equipment required before delivery and upon receipt at the mine.

NOTE Modifications should be re-certified.

D.5 The inspection of Ex equipment

The examples given in (a) to (f) are typical of the information required for the inspection of Ex
equipment.

a) Who is responsible at the mine to carry out inspections on Ex equipment which is in service or
received from a manufacturer or the repairer, by either a visual or other inspection?

b) Who are the required personnel to carry out this work?

c) What are the necessary qualifications, training and competencies of the appointed persons?

d) In accordance with which standards and procedures are the appointed persons required to do
the inspections?

e) What frequency of inspection of equipment in service is required?

f) The type of inspection of equipment before delivery and upon receipt at the mine.

D.6 The maintenance of Ex equipment

The examples given in (a) to (f) are typical of the information required for the maintenance of Ex
equipment.

a) Who is responsible at the mine to carry out maintenance on Ex equipment that is in service?

b) Who are the required personnel appointed to carry out this work?

c) What are the necessary qualifications, training and competencies of the appointed persons?

d) In accordance with which standards and procedures are the appointed persons required to do
the maintenance?

e) What frequency of maintenance on equipment in service is required?

f) What type of maintenance is required?

D.7 Record keeping

The examples given in (a) to (f) are typical of the information required for record keeping of Ex
equipment.

a) Who is responsible at the mine to carry out the record keeping of Ex equipment?

b) Who are the required personnel appointed to carry out this work?

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c) What are the necessary qualifications, training and competencies of the appointed persons?

d) In accordance with which standards and procedures are the appointed persons required to keep
records?

e) What type of record keeping is required?

f) Where are the records to be kept, filed, and stored?

D.8 Procedures
The procedures in (a) to (f) are step-by-step tasks that should be carried out to ensure safe and
correct actions and performance:

a) the procedure should comply with the code of practice;

b) the procedure should describe the tasks of an action;

c) the procedure should indicate the person responsible;

d) the training requirements should be specified;

e) all the necessary safety precautions should be stated;

f) the tools, equipment and materials should be listed.

D.9 Standards

D.9.1 The construction of all explosion-protected electrical equipment and the repair of such
equipment should be in accordance with the applicable standards (see clause 2).

D.9.2 When enquiries for tenders are issued, the mine should take cognizance of the available
mine specifications for the various explosion-protected equipment.

D.9.3 The mine shall take cognizance of the list of approved and contracted companies for the
supply of electrical products and services to specific mines.

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Annex E
(informative)

Typical inspection procedure for periodic inspections

Action Decision

Type: initial Determine provisional

New plant
Grade: detailed periodic interval

Type: sample
Grade: visual

Confirm periodic
Existing interval
plant

Type: periodic
Grade: close Can an increase in No
------------------- the periodic inspection
Type: sample interval be justified?
Grade:detailed

Yes

Increase Has the periodic

periodic No
interval already
interval been 2 years

Type: sample
Grade: visual Yes

Type: periodic
a Can an increase in
Grade: close (I.C. )
------------------------ the periodic inspection
Type: sample interval be justified? No
Grade: detailed

Yes

Carry out safety audit

to recommend new
periodic interval
Drg.921
------------------------
a
I.C.: Ignition is possible in normal operation, i.e. where the internal components of the equipment produce,
in normal operation, arcs, sparks or surface temperatures capable of ignition.
Figure E.1 — Typical inspection procedure for periodic inspections

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Annex F
(informative)

Typical inspection schedules

Tables F.1, F.2 and F.3 show the typical inspection schedules which could be used as a basis when
a mine-specific schedule is designed.

Table F.1 — Inspection schedule for Ex d flameproof installations and

Ex e increased safety installations

1 2 3 4 5 6 7
Ex d Ex e
Inspection Grade of inspection
A Equipment D C V D C V
1. Equipment is appropriate to area classification * * * * * *
2. Equipment group is correct * * * *
3. Equipment temperature class is correct * * * *
4. Equipment circuit identification is available * *
5. Equipment circuit identification is correct * * * * * *
6. Enclosure, glasses and glass to metal sealing gaskets or compounds (or * * * * * *
both) are satisfactory
7. There are no uncertified modifications done * *
8. Bolts, cable entry devices (direct and indirect) and blanking elements are
of the correct type and are complete and tight

• physical check * * * *
• visual check * *
9. Flange faces are clean and undamaged and gaskets, if any, are * *
satisfactory
10. Flange gap dimensions are within permitted maximum * * * *
11. Lamp rating, type and position are correct * *
12. Electrical connections are tight *
13. Condition of enclosure gaskets is satisfactory *
14. Enclosed - break and hermetically sealed devices are undamaged
15. Motor fans have sufficient clearance to enclosure or covers (or both) * *
B Installation
1. Type of cable is appropriate * *
2. There is no obvious damage to cables * * * * * *
3. Sealing of trunking, ducts, pipes or conduits (or both) is satisfactory * * * * * *
4. Earthing connections, including any supplementary earthing bonding
connections are in order (for example, connections are tight and
conductors are of sufficient cross-sectional area)
• physical * *
• visual * * * *
NOTE 1 The meaning of the symbols used to indicate the grades of inspection, are as follows:

D Detailed;
C Close;
V Visual.

NOTE 2 Generally the checks used for equipment using both types of protection "Ex e" and "Ex d" should be a
combination of columns of items B.7 and B.8. Account should be taken of the possibility of an explosive
atmosphere in the vicinity of the equipment when electrical test equipment is used.

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Annex F (continued)

1 2 3 4 5 6 7
Ex d Ex e
Inspection Grade of inspection
D C V D C V
5. Fault loop systems or earthing resistance is satisfactory * *
6. Insulation resistance is in order * *
7. Automatic electrical protective devices operate within permitted limits * *
8. Automatic electrical protective devices are set correctly * *
9. Any special conditions of use are complied with * *
C Environment
1 Equipment is adequately protected against corrosion, vibration and other * * * * * *
adverse factors
2. No undue accumulation of dust and deleterious material * * * * * *
3. Electrical insulation is clean and dry *
NOTE 1 The meaning of the symbols used to indicate the grades of inspection, are as follows:

D Detailed;
C Close;
V Visual.

NOTE 2 Generally the checks used for equipment using both types of protection Ex e and Ex d should be a
combination of columns of items B.7 and B.8. Account should be taken of the possibility of an explosive atmosphere
in the vicinity of the equipment when electrical test equipment is used.

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Annex F (continued)

Table F.2 — Inspection schedule for intrinsically safe Ex i installations,

inspection schedule for Ex d - flameproof installations and
Ex e – increased safety installations

1 2 3 4
Inspection Grade of inspection
A. Equipment D C V
1. Circuit or equipment documentation (or both) is appropriate for the area * * *
classification
2. Equipment installed is that specified in the documentation * *
3. Circuit or equipment (or both) category and group are correct * *
4. Equipment temperature class is correct * *
5. Installation is clearly labelled * *
6. There are no uncertified modifications *
7. Safety barrier units, relays and other energy limiting devices are of the approved * * *
type, installed in accordance with the certification requirements and securely
earthed where required
8. Electrical connections are tight *
9. Printed circuit boards are clean and undamaged *
B. Installation
1. Cables are installed in accordance with the documentation *
2. Cable screens are earthed in accordance with the documentation *
3. There is no obvious damage to cables * * *
4. Sealing of trunking, ducts, pipes or conduits is in order * * *
5. Point-to-point connections are all correct *
6. Earth continuity is satisfactory (for example connections are tight and conductors * *
are of sufficient cross-sectional area
7. Earth connections are as in design and approved drawings * * *
8. The intrinsically safe circuit is isolated from earth or earthed at one point *
9. Separation is maintained between intrinsically safe and non-intrinsically safe *
circuits in common distribution boxes or relay cubicles
10.Short-circuit protection of the power supply is in accordance with the *
documentation
11. Compliance with any special conditions of use *
C Environment
1. Equipment is adequately protected against corrosion, vibration and other adverse * * *
factors
2. No undue external accumulation of dust and deleterious material * * *
NOTE The meaning of the symbols used to indicate the grades of inspection, are as follows (see 6.3):

D Detailed;
C Close;
V Visual.

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Annex F (concluded)

Table F.3 — Inspection schedule for Ex p (pressurized or continuous dilution) installations,

inspection schedule for Ex d - flameproof installations and
Ex e – increased safety installations

1 2 3 4
Inspection Grade of inspection
A Equipment D C V
1. Equipment is appropriate to area classification * * *
2. Equipment group is correct * *
3. Equipment temperature class is correct * *
4. Equipment circuit identification is available * *
5. Equipment circuit identification is correct * * *
6. Enclosure, glasses and glass to metal sealing gaskets or compounds (or both) * * *
are satisfactory
7. There are no uncertified modifications *
9. Lamp rating, type and positions are correct *
B Installation
1. Type of cable is appropriate *
2. There is no obvious damage to cables * * *
3. Earthing connections, including any supplementary earthing bonding connections
are in order, for example connections are tight and conductors are of sufficient
cross-sectional area
• physical check * * *
• visual check * * *
4. Fault loop impedance (IN systems) or earthing resistance (IT systems) is *
satisfactory
5. Automatic electrical protective devices operate within permitted limits *
6. Automatic electrical protective devices are set correctly *
7. Protective gas inlet temperature is below maximum specified *
8. Ducts, pipes and enclosures are in good condition * * *
9. Protective gas is substantially free from contaminants * * *
10. Protective gas pressure or flow (or both) is adequate * * *
11. Pressure or flow indicators (or both), alarms and interlocks function correctly *
12. Pre-energizing purge is adequate *
13. Compliance with any special conditions of use *
C Environment
1. Equipment is adequately protected against corrosion, weather, vibration and other * * *
adverse factors
2. No undue accumulation of dust and deleterious material * * *
NOTE 1 The meaning of the symbols used to indicate the grades of inspection, are as follows (see 6.3):

D Detailed;
C Close;
V Visual.

NOTE 2 IN and IT are system earthing identification codes. See 5.1 in SANS 10292:2001 for descriptions.

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Annex G
(informative)

Typical in-process risk assessment

DATE: ........................................................................................................................................

SITE: ..........................................................................................................................................

CONTRACTOR: ........................................................................................................................

ASSESSMENT TEAM: ..............................................................................................................

....................................................................................................................................................

TASK TO BE ASSESSED: ........................................................................................................

....................................................................................................................................................

TOOLS AND EQUIPMENT INVOLVED: ...................................................................................

....................................................................................................................................................

NEEDED

REASON FOR ASSESSMENT:

New task
Dangerous task
Change in process
New team

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Table G.1 — Steps of in-process risk assessment, risk rating

1 2 3 4 5 6 7 8
No. Step Risks identified A B C Remedial actions Responsible person

NOTE The key that can be used to indicate probability and consequence, is as follows:

A1 Not likely
A2 50/50 chance
A3 Can easily occur
B1 Minor injury
B2 Serious injury
B3 Death or permanent
C1-2 Under control
C3-4 Control needed
C5-6 Implement control immediately or discontinue task

SANS 10086-2:2013
Edition 2

Annex H
(informative)

Typical task observation or written safe work procedure

H.1 Typical task observation
Task to be observed: .................................................................................................................

Date: ..........................................................................................................................................

Time: ..........................................................................................................................................

Required for task Right Wrong Task observation:

Planned
Unplanned

I, the undersigned, declare that a task observation was done on the work being conducted by me as
specified above and that the deviations from the set procedure were communicated to me and that I
understand what I did wrong and can now carry out the task correctly.

Person observed: Signature:

Observer: Signature:

Safety officer: Signature:

YES NO
Has a serious shortcoming in the procedure been identified:?

What immediate action was taken to remedy the shortcoming? ...............................................

....................................................................................................................................................

What action was taken to address the problem in the long term? ...............................................

.......................................................................................................................................................

To the observer:

When doing a task observation you should:

a) Tell the person to be observed what you are about to do.

b) Tell the person what specific task you will be observing.

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Annex H (continued)

c) Ask the person to tell and show you what PPE is required for the task.

d) Write down the steps as the person performs the tasks and ask him why he does things in the
way he does.

e) Make clear notes on the exceptions to the rules and correct the person where he does
something incorrectly. Make clear notes on any shortcomings in the existing procedure.

f) After the task observation has been completed, ask the person to relate to you the correct way
of carrying out the tasks. Correct any deviations and discuss the reasons for doing the task
correctly.

g) Ask the person to countersign the task observation and explain that it serves as a training
session.

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Table H.1 — Typical task observation and written safe work procedure

1 2 3 4 5 6 7 8
Work procedure Task observation
Responsible Correct Corrective action taken or
No. Step Risks Recommendations
person Yes No training given

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Annex I
(normative)

Safety precautions (lock-out procedures, gas testing, NER tests)

I.1 General
National legislation (see foreword) requires that equipment be de-energized before being worked on
in order to protect the health and safety of persons. For this purpose it is required that the appointed
competent person complies with a code that details the procedures to be followed when such work
is to be done.

This annex stipulates the minimum requirements for such a code.

I.2 Lock-out system

I.2.1 A lock-out system is applicable to, but not limited to, an electrical system, a mechanical
system, a chemical plant, hydraulic and pneumatic systems, and self-propelled mobile machinery.

I.2.2 There are many instances when plant equipment needs to be isolated for repair, inspection,
tests, modifications or maintenance (or both). The following requirements shall be strictly adhered
to:

a) the code shall be drawn up for each type of equipment; and

b) the code shall specify who shall use the equipment, where it shall be used and how the
equipment shall be isolated.

I.3 Identification of equipment

I.3.1 In cases where the person tasked to isolate the equipment is different from the person who
works on the equipment, it is important that the correct equipment be isolated.

I.3.2 Where equipment is duplicated for standby reasons, the equipment shall be marked properly.

NOTE Care should be taken when work is done on ring feed and parallel feed systems where there might be
more than one point of supply.

I.4 Lock-out device

I.4.1 The lock-out device shall make provision for more than one person to lock out the equipment
when more than one person will be working on that particular equipment.

I.4.2 If a padlock is used, only the person who is working on the equipment shall be in possession
of the key.

I.4.3 The isolation shall be such that even remote or automatic start-up will be rendered ineffective
and the following shall apply:

a) when the equipment cannot be locked out at the point of isolation, the supply cable shall be
disconnected;

b) lock out shall be carried out on the power circuit and not on the control circuit of the electrical
supply to the equipment;

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c) on a pipeline, the use of “slip plates” or blanking off is good practice in addition to an isolation
valve locked with a chain and lock;

d) where equipment is sequence-interlocked, the equipment before and after the equipment to be
worked on shall also be isolated; and

e) on electrically operated self-propelled mobile machines the trailing cable plug shall be removed
and a device fitted over the plug and pad-locked.

I.5 Isolation record book

I.5.1 A person who works on equipment shall enter the following relevant details into an isolation
record book (IRB):

a) the name (print);

b) the date;

c) the time; and

d) the equipment being isolated.

I.5.2 Each person shall clear the IRB when the job has been completed, by entering the name
(print), date and time. An engineer or person appointed shall scrutinize the IRB at defined intervals.

I.5.3 In the case of mobile equipment, the engineer or person appointed shall scrutinize the driver’s
checklist to verify if the equipment is still fit for purpose.

I.6 Test
The isolated plant shall be tested, discharged and earthed before the commencement of work in
order to ensure that the equipment to be worked on is in fact de-energized.

I.7 Warning sign

A warning sign shall be posted at the point of isolation stating that machinery has been de-
energized and isolated because work is in progress.

I.8 Energizing procedure

In a hazardous area the re-energizing procedure shall include the relevant gas testing procedure.

I.9 Implementation

I.9.1 The proper implementation of the lock-out system cannot be over emphasized. Personnel on
the mines shall be educated and trained on the system. The system shall be supervised to check
that it is correctly implemented by means of task observation. It shall be ensured that the system is
reviewed and revised as the need arises.

I.9.2 The lock-out system is part of a broader system that needs to be integrated with other
systems by means of procedures.

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Annex J
(informative)

IEC
Scope for certified person scheme

MANUFACTURING INSTALLATION USE OF EQUIPMENT/

Product design Correct selection MAINTENANCE
Manufacture of product Correct installation Maintenance, repair, overhaul
Placing on the market Installation documentation
SANS 60079 series of Documentation Competent to apply standards, e.g.
documents Competent to apply standards, e.g. SANS 60079- 17,SANS 60079-19
SANS 60079- 10, SANS 60079-14,
SANS 60079- 17

STATUTORY REQUIREMENTS(see foreword) in South Africa

REGULATIONS (see
foreword) in South Africa

SANS10108: The SANS 10086- 1 SANS 10142- 1

classification of hazardous The installation, inspection and The wiring of
locations and the selection maintenance of equipment used in premises
of apparatus for use in such explosive atmospheres Part 1: Low -
locations Part 1: Installations including surface voltage
ARP 0108 Recommended installations on mines installations
practice. Regulatory SANS 10108, SANS 10142 - 1,
requirements for explosion- SANS 60079-14, SANS 60079-17
protected apparatus.

SANS 10108 SANS 10086- 2

4.1 Explosive atmosphere - Classification of The installation, inspection and
areas - Explosive gas atmospheres (all maintenance of equipment used in
indusdries except mining). All requirements explosive atmospheres
in SANS 60079-10 - 1 shall apply. Part 2: Electrical apparatus
installed underground in mines.

SANS 10108: The classification of

SANS 10108 SANS 10086- 3
hazardous locations
4.2 Explosive and the
atmosphere selection of of
- Classification The installation, inspection and maintenance of
equipment for use in such
areas - Combustible locations
dust (all industries equipment used in explosive atmospheres
ARP 0108mining).
except Recommnded practice in
All requirements Part 3: Repair and overhaul of equipment
Regulatory requirements
SANS 60079-10-2 shall for explosion-
apply. SANS 10108, ARP 0108, SANS 60079-19
protected apparatus
Drg.921a

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Bibliography
SANS 10292, Earthing of low-voltage (LV) distribution systems.

SANS 10347, Avoidance of hazards underground in collieries due to lightning.

SANS 60079-4/IEC 60079-4, Electrical apparatus for explosive gas atmospheres – Part 4: Method
of test for ignition temperature.

SANS 60079-10-1/IEC 60079-10-1, Explosive atmospheres – Part 10-1: Classification of areas –

Explosive gas atmospheres.

SANS 60079-10-2/IEC 60079-10-2, Explosive atmospheres – Part 10-2: Classification of areas –

Combustible dust atmospheres.

SANS 60079-14/IEC 60079-14, Explosive atmospheres – Part 14: Electrical installations design,
selection and erection.

SANS 60079-17/IEC 60079-17, Explosive atmospheres – Part 17: Electrical installations inspection
and maintenance.

SANS 60079-19/IEC 60079-19, Explosive atmospheres – Part 19: Equipment repair, overhaul and
reclamation.

SANS 60079-20-1/IEC 60079-20-1, Explosive atmospheres – Part 20-1: Material characteristics for
gas and vapour classification – Test methods and data.

SANS 60269-1/IEC 60269-1, Low-voltage fuses – Part 1: General requirements.

SANS 60269-2/IEC 60269-2, Low-voltage fuses – Part 2: Supplementary requirements for fuses for
use by authorized persons (fuses mainly for industrial application) – Examples of standardized
systems of fuses A to J.

SANS 62305-1/IEC 62305-1, Protection against lightning – Part 1: General principles.

SANS 62305-2/IEC 62305-2, Protection against lightning – Part 2: Risk management.

SANS 62305-3/IEC 62305-3, Protection against lightning – Part 3: Physical damage to structures
and life hazard.

SANS 62305-4/IEC 62305-4, Protection against lightning – Part 4: Electrical and electronic systems
within structures.

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