Open Cut

Stage Two Report: 11 KV Cable Coupler Systems and Stage One Report: 3.3kV 425 Amp Coupler System

Open Cut » Maintenance & Equipment

Published: March 18Project Number: C20030

Get ReportAuthor: Stephen Williams | Connec

STAGE 2 REPORT - 11 KV Cable Coupler Systems

There has been insufficient product innovation over the last 25 years to improve mining cable connectors in order to reduce the incidence of cable arcing incidents. These incidents have the capacity to ignite coal dust or flammable gases, which could result in explosion, leading to serious personal injury or catastrophic loss of life. In addition, due to the expansion of the mining industry over this period, there is a changing risk profile in the field. This requires the industry to look further to improve incident control measures.

Connec, have designed, constructed and certified a series of cable plugs and receptacles which use technological advancements to overcome some of the inherent limitations in current designs in operation. This has included a Type B 3.3 kV restrained coupler system as well as a 11kV bolted coupler system.

Connec's Type B 11 kV Bolted Coupler System (BCS) continued the technical evolution initiated with the ANZEx/IECEx certified Type B 3.3 kV Restrained Coupler System (RCS). The BCS has added further technical and OHS improvements utilising the same modern moulding techniques and methodologies utilised on the RCS polymer products.

Prototyping and subsequent testing of Connec's coupler systems provided validation of the design, enabling product trials to commence as well as realising production units for submission to the test station for certification. Industry engagement was sought throughout the entire design process to ensure the product built was fit for purpose. Product trials ensured the design was proven in the field prior to full production thus eliminating any in‐service issues that may arise through the introduction of the new connector system.

The BCS completed testing and certification at SIMTARs for compliance to the following Standards in December 2017:






STAGE 1 REPORT (June 2015) - 3.3kV 425 AMP Coupler System


Global growth and infrastructure development depends heavily on mined natural resources such as minerals, metal ores, and coal. Demand for Australia's commodities has led to more mines and an increased consumption of electrical energy associated with the mining extraction processes. The increased demand has led to the effect of increasing the size, power rating and complexity of a typical mine's electrical system through larger more efficient mining machines, larger cables and reticulation networks working continuously in demanding conditions. The consequence of a changing market has led to a changing mining risk profile and the potential opportunity to look for innovative ways to adapt to these changes and improve mine safety.

The need for innovation in the area of power cables and their interconnection has led to the development of the Connec coupler system.

Connec has designed, manufactured, tested and installed a 3.3kV 425 Amp coupler system. Connec's intention was to remove the reliance on metallic components and have polymer components fulfilling structural requirements of the design wherever possible. The Coupler system has been designed to incorporate the technical improvements originally conceptualized at the inception of this project which have produced reduced cost, increased efficiency, reduced the chance of injury, and potentially save lives:

  • Injury Prevention - reduced, weight, size and heat.
  • Efficiency -reduced time for installation and fit out.
  • Safety & Performance - reduced explosive risk
  • Cost - increased application

The coupler system is subject to certification by Simtars Australia for compliance to the following Standards:







Health and safety, productivity and environment initiatives.


Open Cut

Safety, productivity and the right to operate are priorities for open cut mine research.

Recently Completed Projects

C19024Establishing Ecologically Sustainable Mine Water Release Criteria In Seasonally Flowing Streams

Extreme rainfall conditions in the Fitzroy Catchment over an approxi...

C25030Coal Mine Open Pit Final Void Closure And Relinquishment - Addressing Uncertainty In Coal Mine Environmental Planning

This report addresses uncertainties faced by coal mine operators whe...

C27046Estimation Of True Deformation Vector From Slope Radar Monitoring

Slope deformation radar monitors are now widely used in open cut coa...

Open Cut

Coal Preparation

Maximising throughput and yield while minimising costs and emissions.

Recently Completed Projects

C27004Improving Coal Flotation With Oscillatory Air Supply

This report provides detailed information on coal flotation with os...

C25018Improving Solids Recovery And Moisture Reduction In Ultrafine Coal Dewatering

This report provides detailed information on fine coal dewatering in...

C27028Lab Froth Flotation Testing Guide With Coal Quality

Correct outcomes from laboratory froth flotation testing in coal bor...

Coal Preparation

Technical Market Support

Market acceptance and emphasising the advantages of Australian coals.

Recently Completed Projects

C26039Nanoporosity In Cokes: Their Origin, Control And Influence On CO2 Reactivity

This project using the outcomes of previous project C24060, examine...

C28063A Comprehensive Technical Review Of High-Efficiency Low-Emission (HELE) Pulverised Coal Combustion Technologies For Power Generation

Research and development has been undertaken worldwide to realise co...

C28064Carbon Structure Transformation During Coking Of Australian Coking Coals: Better Understanding The Coke Formation

Carbon structures of coke that are formed during the plastic layer a...

Technical Market Support

Mine Site Greenhouse Gas Mitigation

Mitigating greenhouse gas emissions from the production of coal.

Recently Completed Projects

C28076Selective Absorption Of Methane By Ionic Liquids (SAMIL) - Phase 2 Demonstration In A Packed Bed Reactor

An alternative approach to high temperature oxidation of ventilation...

C26004CFD Modelling Of Reverse Thermal Oxidisers For VAM Abatement - CFD Modelling Of Fixed-Bed RTO Devices

The project is part of a larger multi‐phase program of study a...

C27058Technological Assessment Of A Recycle Reactor For VAM Abatement

Underground coal mining emits high volumes of methane, diluted in ve...

Mine Site Greenhouse Gas Mitigation

Low Emission Coal Use

Step-change technologies aimed at reducing greenhouse gas emissions.

Recently Completed Projects

C17060BGasification Of Australian Coals

Four Australian coals were trialled in the Siemens 5 MWth pilot scale ga...

C17060AOxyfuel Technology For Carbon Capture And Storage Critical Clean Coal Technology - Interim Support

The status of oxy-fuel technology for first-generation plant is indicate...

C18007Review Of Underground Coal Gasification

This report consists of a broad review of underground coal gasification,...

Low Emission Coal Use

Mining And The Community

The relationship between mines and the local community.

Recently Completed Projects

C16027Assessing Housing And Labour Market Impacts Of Mining Developments In Bowen Basin Communities

The focus of this ACARP-funded project has been to identify a number...

C22029Understanding And Managing Cumulative Impacts Of Coal Mining And Other Land Uses In Regions With Diversified Economies

The coal industry operates in the context of competing land-uses that sh...

C23016Approval And Planning Assessment Of Black Coal Mines In NSW And Qld: A Review Of Economic Assessment Techniques

This reports on issues surrounding economic assessment and analysis ...

Mining And The Community


National Energy Research,Development & Demonstration Council (NERDDC) reports - pre 1992.

Recently Completed Projects

1609-C1609Self Heating of Spoil Piles from Open Cut Coal Mines

Self Heating of Spoil Piles from Open Cut Coal Mines

1301-C1301Stress Control Methods for Optimised Development...

Stress Control Methods for Optimised Development and Extraction Operations

0033-C1356Commissioned Report: Australian Thermal Coals...

Commissioned Report: Australian Thermal Coals - An Industry Handbook