Introduction

In the demanding environments of mining and heavy industries, reliable and resilient electrical systems are the lifeblood of operations. From massive excavation machinery and conveyor belts to processing plants and smelting facilities, robust power infrastructure is essential for continuous production, optimal safety, and economic viability. These sectors face unique electrical challenges, including harsh operating conditions, extreme loads, significant transient events, and often remote locations, all while adhering to stringent safety regulations. The sheer scale and criticality of the equipment demand specialized knowledge in high-voltage distribution, motor control, power quality management, and comprehensive protection schemes to prevent costly downtime and ensure personnel safety. Without a deep understanding of Electrical Systems for Mining and Heavy Industries, engineers, plant managers, and maintenance personnel risk operational inefficiencies, frequent equipment failures, and an inability to meet production targets, underscoring the vital need for specialized expertise in this challenging domain. This comprehensive training course focuses on equipping professionals with the expertise to master Electrical Systems for Mining and Heavy Industries.

This training course is meticulously designed to empower electrical engineers, operations managers, maintenance supervisors, project managers, and technical specialists within the mining, metals, cement, and other heavy industrial sectors with the theoretical understanding and practical insights necessary to effectively design, manage, and optimize Electrical Systems for Mining and Heavy Industries. Participants will gain a comprehensive understanding of power generation and distribution in large industrial complexes, learn about robust motor control centers, delve into hazardous area classifications, and acquire hands-on experience in selecting, installing, and maintaining electrical equipment in demanding industrial environments. The course will cover topics such as high-voltage switchgear, protective relaying, power quality mitigation, earthing and bonding, emergency power systems, compliance with relevant international and industry standards, and critical electrical safety procedures specific to heavy industry. By mastering the principles and practical application of Electrical Systems for Mining and Heavy Industries, participants will be prepared to enhance operational reliability, improve safety performance, optimize energy consumption, and contribute significantly to the efficient and secure functioning of critical industrial assets.

Duration: 10 Days

Target Audience

• Electrical Engineers (Mining, Metals, Cement, Heavy Manufacturing)
• Plant Managers and Operations Superintendents
• Maintenance Managers and Supervisors (Electrical)
• Project Managers for Industrial Expansion/Upgrade
• Reliability Engineers
• Control System and Automation Engineers
• Safety Officers (Electrical Safety Focus)
• Consulting Engineers specializing in Industrial Power
• Technical Specialists (Electrical, Mechanical)
• Graduates entering Heavy Industries

Objectives

• Understand the unique electrical demands and operating environments of mining and heavy industries.
• Learn about high-voltage power distribution systems in large industrial complexes.
• Acquire skills in designing and selecting motor control systems for heavy machinery.
• Comprehend techniques for protective relaying and fault analysis in industrial power networks.
• Explore strategies for managing power quality issues (harmonics, voltage sags) in heavy industrial loads.
• Understand the importance of earthing, bonding, and lightning protection in harsh environments.
• Gain insights into emergency power systems and critical load management.
• Develop a practical understanding of hazardous area classification and explosion protection.
• Learn about electrical safety procedures and relevant industry standards.
• Master energy efficiency strategies for large industrial electrical loads.
• Acquire skills in diagnosing and troubleshooting common electrical failures.
• Understand the application of SCADA and automation in industrial electrical control.
• Explore advanced electrical equipment for mining and heavy industries.
• Develop proficiency in asset integrity management for electrical systems.
• Prepare to optimize reliability, safety, and efficiency of electrical systems in challenging industrial settings.

Course Content

Module 1: Introduction to Electrical Systems in Mining & Heavy Industries

• Overview of power demands in various heavy industries (mining, steel, cement, pulp & paper).
• Key electrical challenges: harsh environment, heavy loads, continuous operation, safety.
• Evolution of electrical technology in industrial applications.
• Importance of reliability, safety, and energy efficiency.
• Relevant international and industry standards (IEC, IEEE, NFPA, local codes).

Module 2: High Voltage (HV) Power Distribution Systems

• Substation design and layout for industrial applications.
• Types of HV switchgear (GIS, AIS) and circuit breakers.
• HV cabling: types, sizing, installation, and protection.
• Overhead lines vs. underground cables for industrial distribution.
• Arc flash hazards in HV systems.

Module 3: Medium Voltage (MV) Distribution and Motor Control Centers

• MV switchgear and protection in industrial facilities.
• MV motor control centers (MCCs) and their components.
• Design of motor starters: direct online, star-delta, soft starters, VFDs.
• Applications of MV motors in heavy industry (crushers, mills, pumps).
• Retrofitting and upgrading MV systems.

Module 4: Low Voltage (LV) Power Distribution and MCCs

• Design of LV switchboards, panel boards, and MCCs.
• Cable sizing, voltage drop, and fault current calculations for LV systems.
• Circuit breakers, fuses, and protective devices.
• Power factor correction at the LV side.
• Distributed control and intelligent MCCs.

Module 5: Industrial Electric Motors and Variable Speed Drives (VSDs)

• Types of motors: induction, synchronous, DC, and their applications.
• Principles of VSDs/VFDs for energy efficiency and process control.
• Sizing and selection of motors and drives for heavy industrial loads.
• Harmonic distortion introduced by VSDs and mitigation techniques.
• Maintenance and troubleshooting of motors and drives.

Module 6: Protective Relaying and System Fault Analysis

• Principles of protective relaying for industrial power systems.
• Types of relays: overcurrent, differential, distance, earth fault.
• Coordination of protective devices for selectivity and speed.
• Short circuit fault analysis (symmetrical and asymmetrical faults).
• Ground fault protection and its importance in industrial settings.

Module 7: Power Quality Management in Heavy Industries

• Common power quality issues: harmonics, voltage sags, swells, transients.
• Impact of power quality on industrial equipment and processes.
• Harmonic mitigation strategies: passive and active filters.
• Voltage regulation and stabilization techniques.
• Power quality monitoring and analysis.

Module 8: Earthing, Bonding, and Lightning Protection

• Importance of effective earthing and bonding for safety and equipment protection.
• Design of earthing grids for industrial plants.
• Lightning protection systems for industrial structures.
• Surge Protective Devices (SPDs) for transient voltage protection.
• Special considerations for earthing in mining operations.

Module 9: Emergency Power Systems and UPS

• Sizing and selection of standby generators for critical loads.
• Automatic Transfer Switches (ATS) and paralleling switchgear.
• Uninterruptible Power Supply (UPS) systems for essential controls and safety systems.
• Battery systems for UPS and control power.
• Emergency lighting and egress systems.

Module 10: Hazardous Area Classification and Explosion Protection

• Understanding flammable atmospheres in mining (methane, coal dust) and heavy industries (solvents, gases).
• Principles of hazardous area classification (Zones, Divisions).
• Explosion protection concepts (Ex d, Ex e, Ex i, Ex p).
• Selection, installation, and maintenance of electrical equipment in hazardous areas.
• Relevant standards: ATEX, IECEx, NEC.

Module 11: Electrical Safety in Mining and Heavy Industries

• Electrical hazards: electrocution, arc flash, fire, explosion.
• Lockout/Tagout (LOTO) procedures for electrical isolation.
• Permitting systems for electrical work (e.g., PTW).
• Arc flash risk assessment and Personal Protective Equipment (PPE).
• Compliance with safety regulations and standards.

Module 12: Energy Efficiency and Optimization

• Energy auditing for industrial electrical systems.
• Strategies for reducing energy consumption: efficient motors, VSDs, lighting.
• Power factor correction for improved efficiency.
• Waste heat recovery and cogeneration (CHP).
• Energy management systems and monitoring.

Module 13: SCADA, Automation, and Industrial Control

• Role of SCADA (Supervisory Control and Data Acquisition) in electrical system control.
• Programmable Logic Controllers (PLCs) for process automation.
• Human Machine Interface (HMI) for operator control.
• Integration of electrical systems with plant-wide automation.
• Cybersecurity for industrial control systems.

Module 14: Maintenance, Reliability, and Asset Integrity

• Preventive, predictive, and proactive maintenance strategies for electrical equipment.
• Condition monitoring techniques (thermal imaging, vibration analysis, partial discharge).
• Root Cause Failure Analysis (RCFA) for electrical failures.
• Asset integrity management for aging electrical infrastructure.
• Spare parts management and critical spares identification.

Module 15: Future Trends and Case Studies

• Digitalization and Industry 4.0 in industrial electrical systems.
• Renewable energy integration for industrial power supply.
• Battery Energy Storage Systems (BESS) in heavy industry.
• Automation and robotics in hazardous electrical environments.
• Case studies of successful electrical system projects and upgrades in mining/heavy industries.

Training Approach

This course will be delivered by our skilled trainers who have vast knowledge and experience as expert professionals in the fields. The course is taught in English and through a mix of theory, practical activities, group discussion and case studies. Course manuals and additional training materials will be provided to the participants upon completion of the training.

Tailor-Made Course

This course can also be tailor-made to meet organization requirement. For further inquiries, please contact us on: Email: info@skillsforafrica.org, training@skillsforafrica.org  Tel: +254 702 249 449

Training Venue

The training will be held at our Skills for Africa Training Institute Training Centre. We also offer training for a group at requested location all over the world. The course fee covers the course tuition, training materials, two break refreshments, and buffet lunch.

Visa application, travel expenses, airport transfers, dinners, accommodation, insurance, and other personal expenses are catered by the participant

Certification

Participants will be issued with Skills for Africa Training Institute certificate upon completion of this course.

Airport Pickup and Accommodation

Airport pickup and accommodation is arranged upon request. For booking contact our Training Coordinator through Email: info@skillsforafrica.org, training@skillsforafrica.org  Tel: +254 702 249 449

Terms of Payment: Unless otherwise agreed between the two parties’ payment of the course fee should be done 10 working days before commencement of the training.