AS/NZS 1747标准下的护套修复：241型电缆在危险区域的冷浇注树脂应用
Anhui Feichun Special Cable Co., Ltd.
Sheath Repair Under AS/NZS 1747: Cold Pour Resin Application for Type 241 Cables in Hazardous Zones
AS/NZS 1747标准下的护套修复：241型电缆在危险区域的冷浇注树脂应用
Executive Summary
概述
The question of whether cold pour resin can be used to repair the sheath of Type 241 cables in hazardous zones under AS/NZS 1747 is a critical concern for mining operations, particularly in underground coal mines where explosion-protected equipment is mandatory. This technical analysis examines the regulatory framework, repair methodologies, and safety considerations governing cable sheath repair in potentially explosive atmospheres.
在AS/NZS 1747标准下，是否可以使用冷浇注树脂修复危险区域中241型电缆的护套，这是采矿作业的关键问题，特别是在要求防爆设备的地下煤矿中。本技术分析探讨了在潜在爆炸性环境中管理电缆护套修复的监管框架、修复方法和安全考虑。
Cable repairs in hazardous zones must comply with AS/NZS 60079 series standards for electrical equipment in explosive atmospheres, in addition to AS/NZS 1747 requirements. Any repair methodology must be assessed against the specific zone classification and must not compromise the cable’s electrical integrity or mechanical protection.
危险区域的电缆修复必须符合AS/NZS 60079系列关于爆炸性环境电气设备的标准，以及AS/NZS 1747的要求。任何修复方法都必须根据具体的区域分类进行评估，不得损害电缆的电气完整性或机械保护。
Understanding AS/NZS 1747:2022 Standard
了解AS/NZS 1747:2022标准
AS/NZS 1747:2022 establishes comprehensive requirements for the repair and testing of reeling, trailing, and feeder cables used in underground coal mines, metalliferous mines, open cut mines, tunneling operations, quarries, and dredges. The standard is specifically designed to ensure that repaired cables maintain their original safety and performance characteristics throughout their operational life.
AS/NZS 1747:2022为地下煤矿、金属矿、露天矿、隧道工程、采石场和挖泥船中使用的卷筒电缆、拖曳电缆和馈线电缆的修复和测试制定了全面的要求。该标准专门设计以确保修复后的电缆在整个使用寿命中保持其原始的安全性和性能特征。
Latest revision: January 2022
Underground coal, metalliferous, quarries, dredges
Type 241 cable specifications
Insulation resistance, earth continuity verification
Type 241 Cable Specifications
241型电缆规格
Type 241 cables are semiconductive screened cables manufactured according to AS/NZS 1802:2003 standards, designed for general use in underground coal mining operations. These cables typically serve as main feeder cables for continuous miners, pump power supplies, and general-purpose distribution circuits. The cable construction incorporates multiple layers of protection to ensure reliable operation in the demanding underground mining environment.
241型电缆是根据AS/NZS 1802:2003标准制造的半导电屏蔽电缆，专为地下煤矿作业的一般用途而设计。这些电缆通常用作连续采煤机的主馈线电缆、泵电源和通用配电回路。电缆结构包含多层保护，以确保在要求苛刻的地下采矿环境中可靠运行。
| Component 组件 | Material 材料 | Specification 规格 |
|---|---|---|
| Conductor 导体 | Tinned Copper 镀锡铜 | Flexible stranded, AS/NZS 1125 compliant |
| Conductor Screen 导体屏蔽 | Semiconductive Tape 半导电带 | 1.1/1.1kV: polyester barrier tape ≥3.3/3.3kV: extruded semiconductive |
| Insulation 绝缘 | EPR (R-EP-90) | Ethylene Propylene Rubber, AS/NZS 3808 |
| Insulation Screen 绝缘屏蔽 | Semiconductive Tape 半导电带 | Volume resistivity ≤1 Ω·m |
| Sheath 护套 | Heavy-Duty PCP 重型PCP | Polychloroprene thermosetting compound |
| Voltage Rating 额定电压 | — | 1.1/1.1kV to 11/11kV |
| Temperature Range 温度范围 | — | -25°C to +90°C |
Hazardous Zone Classification and Requirements
危险区域分类和要求
Hazardous zones in mining operations are classified according to AS/NZS 60079.10, which defines areas based on the frequency and duration of explosive gas atmosphere presence. Underground coal mines typically contain Zone 1 or Zone 2 classified areas where methane and coal dust create potentially explosive atmospheres. The presence of these flammable gases imposes strict limitations on repair methodologies, particularly those involving heat or potential ignition sources.
采矿作业中的危险区域根据AS/NZS 60079.10进行分类，该标准根据爆炸性气体环境存在的频率和持续时间定义区域。地下煤矿通常包含一区或二区分类区域，其中甲烷和煤尘形成潜在的爆炸性环境。这些可燃气体的存在对修复方法施加了严格的限制，特别是涉及热源或潜在点火源的方法。
| Zone Classification 区域分类 | Definition 定义 | Repair Method Constraints 修复方法限制 |
|---|---|---|
| Zone 0 / 零区 | Explosive atmosphere continuously present or for long periods | No hot work permitted; all operations must be intrinsically safe |
| Zone 1 / 一区 | Explosive atmosphere likely to occur in normal operation | No hot work without gas-free certification; cold shrink/cold pour methods preferred |
| Zone 2 / 二区 | Explosive atmosphere not likely to occur or only briefly if it does | Hot work permitted with precautions and monitoring; all repair methods viable with proper safety measures |
In Zone 1 classified areas, which are common in underground coal mining operations, heat shrink repair methods are typically prohibited due to the hot work requirements. This creates a strong operational preference for cold shrink tubes or cold pour resin systems that eliminate ignition risk while maintaining cable integrity.
在地下煤矿作业中常见的一区分类区域，由于热工作要求，通常禁止使用热缩修复方法。这为冷缩管或冷浇注树脂系统创造了强烈的操作偏好，这些系统消除了点火风险，同时保持了电缆的完整性。
Cold Pour Resin Technology for Cable Sheath Repair
电缆护套修复的冷浇注树脂技术
Cold pour resin systems represent an advanced cable repair technology specifically engineered for applications where heat shrink methods are impractical or prohibited. These systems utilize two-component polyurethane or epoxy resins that cure at ambient temperature through chemical reaction rather than requiring external heat application. The technology has gained significant acceptance in hazardous area applications due to its intrinsic safety characteristics.
冷浇注树脂系统代表了一种先进的电缆修复技术，专门为热缩方法不切实际或被禁止的应用而设计。这些系统利用双组分聚氨酯或环氧树脂，通过化学反应在环境温度下固化，而不需要外部加热。由于其固有的安全特性，该技术在危险区域应用中获得了广泛的认可。
Technical Characteristics of Cold Pour Resin Systems
冷浇注树脂系统的技术特性
| Property 性能 | Specification 规格 | Benefit for Hazardous Zones 危险区域优势 |
|---|---|---|
| Cure Method 固化方法 | Chemical reaction, ambient temperature 化学反应，环境温度 | No ignition source; safe for Zone 1/2 areas 无点火源；适用于一区/二区 |
| Cure Time 固化时间 | 40-60 minutes at 20°C (typical) | Rapid installation; immediate burial capability 快速安装；可立即埋设 |
| Viscosity 粘度 | Low initial viscosity 低初始粘度 | Complete void filling; comprehensive cable interstice penetration 完全填充空隙；全面渗透电缆间隙 |
| Mechanical Protection 机械保护 | Hard-curing resin 硬化树脂 | Superior to heat shrink in impact resistance 优于热缩材料的抗冲击性 |
| Environmental Resistance 环境耐受性 | Hydrocarbon resistant 耐碳氢化合物 | Suitable for mining environment contaminants 适用于采矿环境污染物 |
| Electrical Properties 电气性能 | High dielectric strength 高介电强度 | Maintains insulation integrity 保持绝缘完整性 |
Installation Process and Quality Control
安装过程和质量控制
The installation of cold pour resin systems requires meticulous preparation and execution to ensure repair integrity. The damaged cable section must be thoroughly cleaned, and the repair area must be free from moisture, oils, and contaminants that could compromise adhesion. A three-dimensional gauze or fabric wrap is typically applied around the damaged area to contain the resin during the pour. The two-component resin is mixed according to manufacturer specifications and poured into the prepared cavity, where it flows into all cable interstices and voids before curing.
冷浇注树脂系统的安装需要精心准备和执行，以确保修复的完整性。损坏的电缆部分必须彻底清洁，修复区域必须没有可能影响粘附的水分、油和污染物。通常在损坏区域周围应用三维纱布或织物包裹物，以在浇注期间容纳树脂。双组分树脂按照制造商规格混合，并浇注到准备好的腔体中，在固化前流入所有电缆间隙和空隙。
Regulatory Analysis: AS/NZS 1747 Compliance for Cold Pour Resin
监管分析：冷浇注树脂的AS/NZS 1747合规性
While AS/NZS 1747:2022 provides comprehensive requirements for cable repair and testing, the standard does not explicitly prohibit or endorse specific repair methodologies such as cold pour resin systems. Instead, the standard establishes performance-based requirements that any repair method must satisfy. The critical question becomes whether cold pour resin repairs can meet these performance criteria while maintaining compliance with hazardous area regulations under AS/NZS 60079 series standards.
虽然AS/NZS 1747:2022为电缆修复和测试提供了全面的要求，但该标准没有明确禁止或认可特定的修复方法，如冷浇注树脂系统。相反，该标准建立了任何修复方法必须满足的基于性能的要求。关键问题变成了冷浇注树脂修复是否能满足这些性能标准，同时保持符合AS/NZS 60079系列标准下的危险区域法规。
The permissibility of cold pour resin for Type 241 cable sheath repair in hazardous zones depends on several factors that must be evaluated on a case-by-case basis:
1. Competency Requirements: AS/NZS 4761.1:2018 mandates that personnel performing cable repairs in hazardous areas must possess specific competencies including understanding of explosion protection principles and repair verification procedures. Only qualified technicians may perform such repairs.
2. Post-Repair Testing: AS/NZS 1747:2022 requires mandatory insulation resistance testing, earth continuity verification, and voltage withstand tests after any cable repair. Cold pour resin repairs must demonstrate equivalent or superior performance to original cable specifications.
3. Site-Specific Risk Assessment: Each repair must be evaluated against the specific hazardous area classification, operational conditions, and mine safety management plan requirements. Documentation must be maintained demonstrating compliance with both AS/NZS 1747 and AS/NZS 60079 series standards.
在危险区域使用冷浇注树脂修复241型电缆护套的许可性取决于必须根据具体情况评估的几个因素：1）能力要求；2）修复后测试；3）特定场地风险评估。
Mandatory Testing Requirements Post-Repair
修复后强制测试要求
| Test Type 测试类型 | Requirement 要求 | Acceptance Criteria 验收标准 |
|---|---|---|
| Insulation Resistance 绝缘电阻 | Megohmmeter testing at rated voltage | Minimum 1 MΩ per kV of operating voltage |
| Earth Continuity 接地连续性 | Low-resistance measurement | Earth conductor resistance within specification |
| Voltage Withstand 耐压 | High-potential test at specified voltage | No breakdown or flashover during test period |
| Visual Inspection 目视检查 | Physical integrity assessment | No visible defects, proper resin cure, adequate mechanical protection |
| Documentation 文档记录 | Complete repair records per AS/NZS 1747 | Technician qualification, test results, repair methodology documented |
Comparative Analysis: Repair Methods for Hazardous Zones
比较分析：危险区域的修复方法
The selection of an appropriate cable sheath repair method in hazardous zones requires careful evaluation of multiple factors including safety, performance, installation complexity, and regulatory compliance. Three primary methodologies are commonly considered for mining applications, each with distinct advantages and limitations in hazardous area contexts.
在危险区域选择合适的电缆护套修复方法需要仔细评估多个因素，包括安全性、性能、安装复杂性和监管合规性。通常考虑三种主要方法用于采矿应用，每种方法在危险区域环境中都有不同的优势和局限性。
| Repair Method 修复方法 | Hazardous Zone Suitability 危险区域适用性 | Advantages 优势 | Limitations 局限性 |
|---|---|---|---|
| Heat Shrink 热缩 | Zone 2 only (with precautions) 仅二区（有预防措施） |
• Established technology • Simple application • Widely available materials |
• Requires hot work permit • Prohibited in Zone 0/1 • Gas monitoring essential • Potential ignition source |
| Cold Shrink 冷缩 | Zone 0/1/2 approved 零/一/二区批准 |
• No ignition source • Rapid installation • No special tools required • Pre-expanded tubes |
• Requires cable end access • Not suitable mid-span • Limited mechanical protection • Size-specific tubes needed |
| Cold Pour Resin 冷浇注树脂 | Zone 1/2 suitable 一/二区适用 |
• No ignition source • Superior mechanical protection • Mid-span repair capable • Complete void filling • Hydrocarbon resistant |
• Requires mixing precision • Temperature-dependent cure • Skilled technician essential • Material shelf life limitations |
For Type 241 cables operating in Zone 1 hazardous areas typical of underground coal mines, cold pour resin systems offer the most practical solution when mid-span repairs are required. The technology eliminates ignition risk while providing mechanical protection superior to cold shrink alternatives. However, successful implementation requires proper technician training, adherence to manufacturer specifications, and rigorous post-repair testing per AS/NZS 1747 requirements.
对于在地下煤矿典型的一区危险区域运行的241型电缆，当需要中跨修复时，冷浇注树脂系统提供了最实用的解决方案。该技术消除了点火风险，同时提供优于冷缩替代方案的机械保护。然而，成功实施需要适当的技术人员培训、遵守制造商规格以及符合AS/NZS 1747要求的严格修复后测试。
Conclusion and Recommendations
结论和建议
Based on the regulatory framework analysis and technical evaluation, cold pour resin can be permissible for Type 241 cable sheath repair in hazardous zones under AS/NZS 1747, provided that specific conditions are met. The repair methodology must satisfy both the performance requirements of AS/NZS 1747:2022 and the safety requirements of AS/NZS 60079 series standards for electrical equipment in explosive atmospheres.
基于监管框架分析和技术评估，在满足特定条件的情况下，冷浇注树脂可以在AS/NZS 1747下用于危险区域的241型电缆护套修复。修复方法必须满足AS/NZS 1747:2022的性能要求和AS/NZS 60079系列标准关于爆炸性环境电气设备的安全要求。
Essential Prerequisites for Cold Pour Resin Application
冷浇注树脂应用的基本前提条件
1. Qualified Personnel: Technicians must possess competencies specified in AS/NZS 4761.1:2018 for working with electrical equipment in hazardous areas. This includes understanding explosion protection principles, proper repair techniques, and testing verification procedures.
1. 合格人员：技术人员必须具备AS/NZS 4761.1:2018中规定的在危险区域使用电气设备的能力。
2. Material Specification Compliance: The cold pour resin system must be specifically designed for cable repair applications and demonstrate compatibility with Type 241 cable materials including EPR insulation and PCP sheathing. Manufacturer documentation should confirm suitability for hazardous area use.
2. 材料规格合规性：冷浇注树脂系统必须专门为电缆修复应用设计，并证明与241型电缆材料的兼容性。
3. Comprehensive Testing Protocol: Post-repair testing must include insulation resistance measurement, earth continuity verification, and voltage withstand testing as mandated by AS/NZS 1747:2022. All test results must meet or exceed original cable specifications.
3. 全面测试协议：修复后测试必须包括AS/NZS 1747:2022规定的绝缘电阻测量、接地连续性验证和耐压测试。
4. Documentation and Traceability: Complete records must be maintained documenting the repair methodology, materials used, technician qualifications, test results, and compliance with both AS/NZS 1747 and AS/NZS 60079 requirements. This documentation becomes part of the mine’s safety management system.
4. 文档记录和可追溯性：必须维护完整记录，记录修复方法、使用的材料、技术人员资格、测试结果以及符合AS/NZS 1747和AS/NZS 60079要求的情况。
Final Assessment
最终评估
Cold pour resin technology represents a viable and often preferred solution for Type 241 cable sheath repair in Zone 1 and Zone 2 hazardous areas where traditional heat shrink methods are prohibited or impractical. The technology’s intrinsic safety characteristics, combined with superior mechanical protection and comprehensive void-filling capabilities, make it particularly well-suited for underground coal mining applications. However, implementation success depends critically on proper material selection, qualified technician execution, and rigorous adherence to testing and documentation requirements established by AS/NZS 1747:2022 and related standards.
冷浇注树脂技术代表了在传统热缩方法被禁止或不切实际的一区和二区危险区域进行241型电缆护套修复的可行且通常是首选的解决方案。该技术的固有安全特性，结合优越的机械保护和全面的空隙填充能力，使其特别适合地下煤矿应用。
References and Standards
参考文献和标准
AS/NZS 1747:2022 – Reeling, trailing and feeder cables used for mining – Repair, testing and fitting of accessories
AS/NZS 1747:2022 – 采矿用卷筒、拖曳和馈线电缆 – 修复、测试和配件安装
AS/NZS 1802:2003 – Electric cables – Reeling and trailing – For underground coal mining
AS/NZS 1802:2003 – 电缆 – 卷筒和拖曳 – 用于地下煤矿
AS/NZS 60079 Series – Explosive atmospheres (multiple parts)
AS/NZS 60079系列 – 爆炸性环境（多个部分）
AS/NZS 4761.1:2018 – Competencies for working with electrical equipment for hazardous areas
AS/NZS 4761.1:2018 – 在危险区域使用电气设备的能力
Cable Sheath Repair Technologies – Heat Shrink and Cold Shrink Solutions
电缆护套修复技术 – 热缩和冷缩解决方案
FILOSLIM Cable Sheath Repair Kit – Cold Pour Polyurethane Resin Technology
FILOSLIM电缆护套修复套件 – 冷浇注聚氨酯树脂技术
Australian Electrical Equipment in Hazardous Areas Standards – Technical Reference
澳大利亚危险区域电气设备标准 – 技术参考
Cable Types in AS Standards – Technical Comparison and Applications
AS标准中的电缆类型 – 技术比较和应用
Contact Information
联系信息
For technical inquiries regarding Type 241 cables, AS/NZS standard compliance, or specialized cable solutions for mining applications, please contact Anhui Feichun Special Cable Co., Ltd.
有关241型电缆、AS/NZS标准合规性或采矿应用专用电缆解决方案的技术咨询，请联系安徽飞纯特种电缆有限公司。
![Type 241 mining cables represent a specialized category of flexible power cables designed for demanding underground mining applications, continuous miner feeders, and pump supply systems operating at voltages from 1.1kV to 11kV. These cables are manufactured to comply with AS/NZS 1802:2003 standards and incorporate sophisticated screening systems that balance electrical performance, mechanical flexibility, and safety requirements.[1] （241型矿用电缆是专为严苛的地下采矿应用、连续采矿机馈线和泵供电系统设计的柔性电力电缆，工作电压为1.1kV至11kV）](https://feichuncables.com/blog/wp-content/uploads/image-662-400x225.avif "Composite Screen: How does the copper/nylon braid screen in Type 241 cables handle fault currents compared to a full metallic screen? 2")
![The operational profile of handheld drilling equipment demands cables that can withstand millions of flex cycles without mechanical or electrical failure. A handheld rock drill or roof bolter may be repositioned dozens of times per hour during active operation, with each repositioning imposing multiple flex cycles on the trailing cable. Over the lifetime of the cable, this translates to extreme flex cycle demands that far exceed those imposed on cables serving more stationary equipment. The AS/NZS 1802:2003 standard recognizes this requirement by specifying Type 209 cables as "more suitable as a trailing cable rather than for reeling" and noting that "smaller cables are used for drills and hand held tools and equipment."[9] （手持钻孔设备的操作特性要求电缆能够承受数百万次弯曲循环而不发生机械或电气故障）](https://feichuncables.com/blog/wp-content/uploads/image-663-400x225.avif "Hand-Held Borers: Why is Type 209 (Individually Screened) Mandatory for Handheld Drilling Equipment Instead of Type 275? 3")
