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By Paul Hopton | Principal Electrical Consultant
Mining and quarrying operations are among the most electrically intensive industries, with high-powered equipment, harsh environments, and complex electrical systems. Yet, one of the most underestimated hazards in these settings is the arc flash – a sudden release of electrical energy through the air that can cause catastrophic injuries, equipment damage, and operational downtime.
What Is an Arc Flash?
An arc flash occurs when electrical current jumps through the air between conductors or from a conductor to earth. This can result in:
- Temperatures exceeding 19,000°C
- A pressure wave strong enough to knock workers off their feet
- Molten metal spray and intense light that can cause severe burns and blindness
In mining and quarrying, where electrical systems are often exposed to dust, moisture, vibration, and mechanical wear, the risk of arc flash is significantly elevated.
Why Is the Risk Higher in Mining and Quarries?
- Harsh Environmental Conditions
Dust, humidity, and corrosive elements degrade insulation and enclosures, increasing the likelihood of faults. - Aging Infrastructure
Many sites operate with legacy systems not designed with modern arc flash protection in mind. - Frequent Maintenance and Modifications
Constant equipment relocation and system changes can introduce new hazards if not properly assessed. - Limited Awareness and Training
Electrical safety training often focuses on shock hazards, while arc flash risks remain under-addressed.
Real-World Consequences
Arc flash incidents in mining have led to:
- Fatalities and life-altering injuries
- Extended downtime due to equipment damage and investigations
- Regulatory penalties and reputational harm
These are not just statistics—they are preventable tragedies.
Mitigating the Risk
As professionals, we must lead the charge in reducing arc flash hazards. Key strategies include:
- Conducting Arc Flash Risk Assessments
Use IEEE 1584 to calculate incident energy levels and define PPE requirements. - Implementing Engineering Controls
Protective device changes, remote switching, arc-resistant switchgear, and current-limiting devices can drastically reduce risk. - Enhancing Maintenance Practices
Regular inspections, thermographic surveys, oil sampling, partial discharge trending and proper labelling are essential. - Training and Culture
Empower your teams with knowledge and foster a culture where safety is non-negotiable.
Final Thoughts
Arc flash is not just a technical issue—it’s a human one. In mining and quarrying, where the margin for error is razor-thin, proactive arc flash management can mean the difference between life and death.
Let’s bring this hidden hazard into the spotlight and make our sites safer for everyone.
