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矿山电力系统计算器

设计矿山供电系统——破碎机、提升机、通风机和输送机负载，变压器与开关柜选型，大电机启动校验，VFD 谐波治理及高海拔/粉尘降容，附 BOM 和单线图。

开始计算矿业与重工业解决方案

为什么使用此计算器

矿山兼具最严苛的运行环境和极大且间歇性的电机负载。此计算器汇总破碎机、提升机、风机和输送机负载，应用需用系数和高海拔降容，校验最大电机启动电压跌落，并按 GB 50070 和 IEC 60034 选型变压器、无功补偿和谐波滤波。

Worked Examples

Example 1 — Surface Mine (Crusher + Hoist + Fans + Conveyors) · FOB $313,963

Mining power system · 10kV/0.4kV · Heavy dust · 1500 m

1,600 kVA transformer

S13-M-1600/10 · demand 1,288 kW · VFD 40%

Connected load

1,840 kW

Effective load

1,321 kW

Reactive comp.

626 kvar

Start dip

5.0%

Est. total (FOB)

POA

📦 Bill of Materials

Equipment	Model	Spec	Qty
HV incoming panel	KYN28A-12-630-315	630 A / 31.5 kA · vacuum	1
Main transformer	S13-M-1600/10	1600 kVA · Oil-Immersed · Copper · S13	1
LV incoming panel	GGD-2500	2500 A busbar · In 2309 A	1
LV feeder panel (×2)	GGD-2500	distributes 10 circuits	2
Cable branch box (LV)	DFW-0.4	1-in / 4-out · 0.4 kV · 630 A	2
Main feeder cable (TX→LV)	YJV 0.6/1kV 300 mm² ×5	5× 300 mm² Cu · ΔU 1.80% @ 120 m · $154.0/m	5
Feeder cable — Crusher 1 (×10)	YJV 120 mm²	120 mm² Cu · 238 A · ΔU 2.3% · $68.8/m	10
Branch trunk cable (LV → branch box 1)	YJV 300 mm² ×2	2× 300 mm² Cu · 953 A · ΔU 1.9% · $154.0/m	2
Branch trunk cable (LV → branch box 2)	YJV 300 mm²	300 mm² Cu · 477 A · ΔU 1.9% · $154.0/m	1
Main busbar (Cu)	Cu 125×10	125×10 · 2500 A rating · ref $147.8/m	included
Grounding electrode	Φ20mm × 2.5m rod	R₁ 39.6 Ω → 13 rod(s) ≤ 4 Ω	13
Soft starter cabinet (largest motor)	500 kW	Soft starter (3.0× In) · start dip 5.0%	1
Detuned PFC capacitor bank	626 kvar	automatic · 7% detuned · 0.4 kV	1
Series detuning reactor (7%)	43.8 kvar	189 Hz tuning · below 5th harmonic	1
Active harmonic filter (APF)	300 A	VFD harmonic mitigation (40% VFD load) · GB/T 14549	1

📐 Single-line diagram

⚙️ Electrical schematic (protection & metering)

⛳ Grounding grid layout

🔌 Cable schedule & routing

🗄 Switchgear arrangement

🛡 Protection configuration

📋 Protection settings

Circuit	Protection	Setting	Time	Standard
HV incoming 10 kV	50 instantaneous	739 A	inst	IEC 60255-151 / IEEE 242
HV incoming 10 kV	51 overcurrent	111 A	0.5 s	IEC 60255-151 / IEEE 242
HV incoming 10 kV	51N earth-fault	18 A	0.5 s	IEC 60364-4-41
Transformer 1600 kVA	49 thermal overload	87% of rated	alarm 90%	IEC 60076-7 / IEEE C57.91
LV incoming 0.4 kV	50 instantaneous	18475 A	inst	IEC 60947-2
LV incoming 0.4 kV	51 overcurrent	2771 A	0.3 s	IEC 60947-2 / IEC 60255
LV incoming 0.4 kV	51N earth-fault	462 A	0.3 s	IEC 60364-4-41
Crusher 1	50/51/51N (MCCB)	Ir 262 A - Im 1907 A - Ig 48 A	0.1 s (grading)	IEC 60947-2 / IEC 60255
Crusher 2	50/51/51N (MCCB)	Ir 262 A - Im 1907 A - Ig 48 A	0.1 s (grading)	IEC 60947-2 / IEC 60255
Hoist 1	50/51/51N (MCCB)	Ir 262 A - Im 1907 A - Ig 48 A	0.1 s (grading)	IEC 60947-2 / IEC 60255
Vent fan 1	50/51/51N (MCCB)	Ir 262 A - Im 1907 A - Ig 48 A	0.1 s (grading)	IEC 60947-2 / IEC 60255
Vent fan 2	50/51/51N (MCCB)	Ir 262 A - Im 1907 A - Ig 48 A	0.1 s (grading)	IEC 60947-2 / IEC 60255
Vent fan 3	50/51/51N (MCCB)	Ir 262 A - Im 1907 A - Ig 48 A	0.1 s (grading)	IEC 60947-2 / IEC 60255
+4 more feeders	50/51/51N (MCCB)	per feeder load	0.1 s (grading)	IEC 60947-2

Settings are illustrative starting points — confirm with a protection coordination study per IEC 60255 / IEEE 242.

📚 Calculation book

CALCULATION BOOK

1600 kVA - 10kV/0.4kV - single - illustrative

1. Load calculation

Standard: IEC 60076 - IEC 60364-5-52

Parameter	Formula	Value
Connected load	P = sum(kW)	1,321 kW
Demand factor	Kd	1
Demand power	Pd = P x Kd	1,321 kW
Power factor	cos(phi) before -> after	0.80 -> 0.95
Design apparent power	Sd = Pd / cos(phi)	1,391 kVA
Transformer loading	Sd / Srated	87%

2. Short-circuit calculation

Standard: IEC 60909

Parameter	Formula	Value
System impedance (pu)	Zs = S / Ssc	0.32% (on 1600 kVA base)
Transformer impedance	Zt = Z%	4%
Total impedance	Z = Zt + Zs	4.32%
LV prospective Isc	Isc = In / Z	53.5 kA
HV prospective Isc	Isc = Ssc / (sqrt(3) x V)	28.9 kA
Breaking check	Icu >= Isc	LV 65 kA (1.2x margin) PASS

3. Voltage drop

Standard: IEC 60364-5-52 Annex G

Parameter	Formula	Value
Main feeder	dU = sqrt(3) x I x L x R / V	300 mm2 - dU 1.80% @ 120 m
Limit	max 3%	within limit
Transformer volt. reg.	dU ~ loading x Z% x sin(phi)	1.1% at full load

4. Reactive power / harmonics

Standard: IEC 61921 (PFC) - IEEE 519 (harmonics)

Parameter	Formula	Value
Required compensation	Qc = Pd x (tan1 - tan2)	0 kvar
PFC bank	standard step	0 kvar
Detuned reactor	p = 6%	n/a

5. Grounding

Standard: IEC 60364-5-54 earthing arrangements and protective conductors LV earthing target 10 ohm (TN systems); 4 ohm used as a conservative design target - target 4 ohm

Parameter	Formula	Value
Single rod resistance	R1 = rho/(2 x pi x L) x ln(4L/d)	39.6 ohm
Rods required	n = R1 / (target x 0.8)	13 rod(s) <= 4 ohm
Rod spec	dia x length	20 mm x 2.5 m

This calculation book is illustrative it consolidates the computed values with the referenced standards. A licensed engineer must verify and seal final design documents for construction.

🔧 Secondary schematic (control & signal)

🔩 Terminal strip (typical)

⚙️ Motor starting check (largest motor)

Parameter	Value
Motor	500 kW · started Soft starter (3.0× In)
Starting kVA	1,961 kVA
Feeder short-circuit	500 MVA
Voltage dip	5.0% vs limit 15% — OK ✓

🌀 Reactive & harmonic compensation

Parameter	Value
Reactive compensation	626 kvar detuned bank (7% reactor)
VFD load	40% (528 kW)
Harmonic current	Ih 241 A @ 30% THDi
APF required	Yes — VFD load ≥ 30%

🏔️ Environment & derating

Parameter	Value
Altitude	1500 m → derating factor 0.97
Dust level	Heavy dust → IP54 enclosure
Transformer	S13-M-1600/10 (10/0.4 kV)

📏 Standard basis (依据标准)

Topic	Standard
Standard basis	IEC · IEC 60364-5-52
Conductor ampacity	IEC 60364-5-52 Table B.52.2–B.52.5 (copper, 3 loaded conductors, 30°C ambient, PVC) — typical/rounded values, conservative (±3%)
Voltage-drop limit	IEC 60364-5-52 Annex G · max drop 3%
Winding temp rise	IEC 60076-2 — winding temp rise 65 K (Class A insulation, ONAN)
kVA ratings	IEC 60076-1 R10 preferred numbers
Breaker frames	IEC 60947-2 frame sizes (In)
Grounding target	IEC 60364-5-54 earthing arrangements and protective conductors — LV earthing target ≤ 10 Ω (TN systems); 4 Ω used as a conservative design target · target 4 Ω
Mining power design	GB 50070 — code for design of electric power supply in mines
Rotating machines	IEC 60034 — rotating electrical machines (rating & starting)
Harmonics	GB/T 14549 — quality of electric energy supply: harmonics in public supply network
Power supply design	GB 50052 — code for design of electric power supply systems
Transformers	IEC 60076 — power transformers (altitude / temperature derating)

🧮 How it was calculated

1. Crushers: 2 × 250 kW = 500 kW

2. Hoists: 1 × 500 kW = 500 kW

3. Ventilation fans: 3 × 160 kW = 480 kW

4. Conveyors: 4 × 90 kW = 360 kW

5. Connected load = 1,840 kW → demand = 1,840 × 0.7 = 1,288 kW

6. Altitude derating: 1500 m → factor 0.97 → effective load = 1,288 ÷ 0.97 = 1,321 kW

7. Largest motor start (motor-starting): 500 kW ÷ (0.90×0.85) × 3.0 = 1,961 kVA → dip = 5.0% vs limit 15%

8. Reactive compensation: Qc = 1,321 × (tanφ₁ − tanφ₂) = 626 kvar

9. VFD harmonics: 40% VFD load → Ih = 241 A (30% THDi) · 7% detuned reactor

10. Loads: P=1,321 kW, PF 0.80, 10 circuits

11. Demand: 1,321 × 1 = 1,321 kW

12. Transformer: S = 1,321 ÷ 0.95 = 1390.5 kVA → 1,600 kVA standard

13. Loading: 1,391 ÷ 1,600 = 87% (good range)

14. Voltage regulation: 87% × 4% × sinφ ≈ 1.1% at full load

15. HV: In 92.4 A, Isc 28.9 kA → KYN28A-12-630-315

16. LV: In 2309 A, Isc 53.5 kA (Xfmr Z 4% + system 0.3%) → GGD-2500, 2 feeder panel(s)

17. Cable branch boxes: 2 × DFW-0.4 (1-in/4-out) for feeder grouping

18. Grounding: R₁ 39.6 Ω → 13 rod(s)

19. Main feeder: 5× 300 mm² · ΔU 1.80% — OK

Summary
Estimated total (FOB Qingdao, EXW) — priced equipment				$313,963

📋 Design notes

Pricing basis: FOB Qingdao (EXW) equipment price. Freight, duty and installation are not included — add for landed economics.

Transformer loading: 87% at design demand — good range.

Short-circuit check: HV 28.9 kA vs 31.5 kA (1.1× margin) · LV 53.5 kA vs 65 kA (1.2× margin).

Voltage regulation: ≈ 1.1% at full load (typical limit 5%).

Copper price linkage: Copper-wound transformer price tracks LME copper (current $14,219/t · 2026-09-12 · LME Copper (Sina hf_CAD)).

Parallel conductors: Single-cable ampacity exceeded — parallel conductors specified: main feeder 5× 300 mm², branch trunk 1 2× 300 mm² (per IEC 60364-5-52 / GB 50054).

Cable & grounding pricing: Cable conductors and grounding are priced from the confirmed cables-trays-grounding price reference (per-metre copper YJV; aluminium remains POA). The main copper busbar is POA — its length is project-specific.

Busway (high-current feeders): For LV feeders above ~2500 A, a busway (母线槽) trunking system is recommended instead of parallel cables.

Motor starting: Largest motor 500 kW started Soft starter draws a 5.0% bus dip (within the 15% limit).

Altitude derating: 1500 m elevation → 3% capacity derating applied per IEC 60076 / GB/T 6451 (0.5%/100 m above 1000 m).

Dust protection: Heavy dust environment → specify IP54 enclosure; underground mines should use dry-type transformers (fire safety).

VFD harmonics: 40% VFD load — an active harmonic filter (APF) is recommended to meet GB/T 14549 limits.

Dedicated hoist / crusher drives: Hoists need a regenerative (four-quadrant) VFD to feed lowering energy back to the bus; crushers need a heavy-duty VFD with high overload and load-sharing for multi-motor drives. Both are quoted per project.

Scope: Electrical power side only — mining, hoisting and ventilation mechanical engineering is outside this calculator.

计算过程说明

选型计算原理

设备总容量 = Σ（台数 × kW）。计算负荷 = 设备总容量 × Kd（矿山典型值 0.7）。海拔超过 1000 m 时变压器降容（按 IEC 60076 约 0.5%/100 m），因此有效负荷 = 计算负荷 ÷ 降容系数。最大电机启动容量 = P ÷ (η·cosφ) × kst，母线电压跌落 = Sstart ÷ (Sstart + Ssc)。无功补偿 Qc = P × (tanφ₁ − tanφ₂)；VFD 谐波电流 Ih 采用调谐电抗器组滤波。

适用标准

选型依据 GB 50070（矿山供电设计）、IEC 60034（旋转电机）、GB/T 14549（谐波）、GB 50052（供电设计）和 IEC 60076（变压器降容）。

常见问题

海拔如何影响变压器和开关柜的额定值？

海拔 1000 m 以上空气稀薄，散热和绝缘强度下降。变压器约每升高 100 m 降容 0.5%，开关柜类似。1500 m 站场约降 2.5%，3000 m 约降 10%。计算器按 IEC 60076 与 IEC 62271 对所选变压器和开关柜施加海拔降容。

井下矿山供电的典型电压是多少？

井下矿山以 10 kV 或 6 kV 配电入井，再降压到 1.14 kV 或 0.66 kV 供破碎机、提升机和输送机，0.4 kV 供辅助。长电缆和电机启动宜用较高低压等级。计算器以 10/0.4 kV 地面厂区建模，并对提升机、破碎机做启动压降校核。

矿井提升机为什么需要特殊启动考虑？

矿井提升机（常 500 kW-3 MW）直接启动电流为额定 5-7 倍，可使井下母线跌到 85% 以下并跳掉其他传动。软启动或变频可限制冲击，变压器须按启动 kVA 选型。计算器校核最大电机的压降并据此选供电。

矿山变频器的谐波如何处理？

变频负载占 40% 时 THDi 可超 20%，需配 7% 去谐电容器组或 APF 以满足 IEEE 519（PCC 处 5% THD）。计算器按变频占比配置无功补偿与去谐；重粉尘工况还需 IP54 及以上外壳。

矿山厂区该取多大需用系数？

破碎机、提升机、风机和输送机不会同时达峰，需用系数典型 0.6-0.75。250 kW 破碎机 + 500 kW 提升机 + 160 kW 风机 + 90 kW 输送机的 1600+ kW 装机很少同时超过 60-70%。计算器在选变压器 kVA 前套用 kd。

矿山开关柜需要什么外壳与防护？

矿山开关柜须防尘防潮：地面厂区 IP54/IP55，井下含瓦斯矿井用隔爆 Ex d（IEC 60079）。重粉尘缩短爬电距离，故需加大电气间隙并采用耐漏电绝缘。计算器按粉尘等级在 BOM 中标注对应外壳等级。

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