Mining operations rely heavily on electrical and electronic systems to power equipment, monitor conditions, and ensure worker safety. From surface facilities to underground installations, these environments are exposed to harsh conditions and unpredictable electrical disturbances. One of the most overlooked but critical aspects of electrical safety in mining is surge protection.
Surge events, even brief spikes in voltage, can damage sensitive equipment, disrupt operations, and pose serious safety risks. In mining, where uptime and reliability are essential, protecting systems from transient overvoltages is not optional, it’s a necessity.
What Causes Surges in Mining Environments?
Surges in mining operations can originate from several sources:
- Lightning strikes, especially in remote or elevated sites
- Switching of heavy machinery, such as crushers, conveyors, and pumps
- Faults in power distribution systems
- Electrostatic discharge (ESD) from equipment or personnel
These surges can travel through power lines, signal cables, and control systems, affecting everything from motor drives to communication networks. Read more about whether surge protectors can handle lightning strikes.
Why Mining Equipment Is at Risk
Mining equipment is often deployed in rugged, remote, and high-humidity environments. Electrical systems are exposed to dust, vibration, and temperature extremes, which already challenge their reliability. A surge event can:
- Damage control panels, sensors, and PLCs
- Cause intermittent faults that are difficult to trace
- Lead to unplanned shutdowns and production delays
- Compromise safety systems and emergency controls
In underground operations, where access is limited and downtime is costly, surge-related failures can have serious operational and financial consequences.
Key Areas That Require Surge Protection
Effective surge protection in mining should cover multiple layers of the electrical system:
Power Distribution Panels
Surge protection devices (SPDs) should be installed at main switchboards and distribution panels to shield downstream equipment from voltage spikes.
Motor Control Centers (MCCs)
Heavy-duty motors used in crushers, conveyors, and ventilation systems are vulnerable to switching surges. Protecting MCCs helps maintain equipment longevity and performance.
Field Instrumentation
Sensors and transmitters used for pressure, flow, and environmental monitoring need protection, especially when installed in exposed or underground locations.
Communication and Control Systems
RS485, Ethernet, and other signal lines used for automation and monitoring should be protected to prevent surges from propagating through the network.
Choosing the Right Surge Protectors for Mining
When selecting surge protection for mining applications, consider:
- High durability: Devices must withstand vibration, dust, and moisture
- Voltage rating: Match the SPD to the system’s operating voltage
- Response time: Fast-acting devices offer better protection
- Certification: Look for compliance with IEC 61643 and AS/NZS standards
- Mounting options: DIN rail or panel-mounted units for easy integration
Surge protection should be part of the initial design of electrical systems, not added after failures occur.
Benefits of Using Surge Protection in Mining
Implementing surge protection offers measurable benefits:
- Reduced equipment failure and maintenance costs
- Improved system uptime, especially in remote or underground sites
- Enhanced safety for workers and critical systems
- Compliance with industry standards and insurance requirements
- Long-term cost savings through extended equipment life
In mining operations, where reliability and safety are paramount, surge protection is a critical investment. It safeguards electrical infrastructure from unpredictable voltage spikes, reduces downtime, and ensures continuous operation in demanding environments. Whether you’re designing a new site or upgrading existing systems, integrating surge protection should be a top priority.
At Transtech, we specialise in lightning and surge protection devices, offering solutions such as RJ45 and RS485 surge protectors and lightning protection devices that meet global standards, including IEC, IEEE and ATEX. Our products ensure uninterrupted system operation and long-term reliability, even in harsh environments
Need help on choosing the right surge protection devices for your application?
Contact us today to speak with our specialists, and we’ll help you to select or tailor the appropriate surge protection equipment for your application.