As a result of gradual degradation in the inhospitable environment of the oil industry and frequent handling, irreparable damage occurs to each cable harness. Therefore, a customer from Tashkent approached us with a request for the production of cable harnesses that can be placed in an already operating mining system. It will go through a total overhaul process and the new TENEO cable harnesses will significantly extend its life. The entire solution was custom made from scratch. After obtaining the basic needs of the customer and clarifying the input technical parameters, we prepared a complete project including a combination of suitable wires, steel handles and connectors.

Because the bundles connect the most distant devices at the top of the tower (Top Drive), extreme lengths of cabling were required. It has a length exceeding 1.5 kilometres, of which 580 meters are only for the power cable harness. The length is also reflected in the weight attacking 1.6 tons in the case of a powerful power cable harness. The weight of TENEO drilling rig cable harnesses is not only determined by their length, but also demonstrates the robustness of the design.

TENEO harnesses and EX connectors resist not only aggressive oil industy chemicals, but also withstand harsh mechanical handling. For example, the harnesses must withstand being run over by heavy trucks and cargo vehicles while maintaining their spark-proof features and resistance to electromagnetic interference. We implemented antistatic shielding using 900 meters of special braid manually wound on the cable.

We finished the cables with a combination of industrial connectors of the TENEO TEX - TENEO TSL series for the control cable harnesses and TENEO TEX - TENEO TNR series in the case of the power harness. Thanks to the use of ATEX/iECEX certified TEX connectors, both types of TENEO cable harnesses are fully spark-proof, exceeding the requirements of international standards and compatible with established Amphenol and Winchester standards. The power cable harness can safely transmit currents of up to 1 000 A. The control harness consists of 4 cables that contain up to 50 individual wires.

To attach both types of harnesses to the construction of the mining set, we designed and made special flanges from stainless steel. The customer simply places these 50 kg giant handles into the current structure of the oil tower and thus secures the bundles in place. With no need for any modifications.

The entire solution for a customer from Uzbekistan belongs to our custom-made projects. We sucesfully aim to solve any interconnection need in countless industrial fields.

The mighty TENEO power cable harness will serve for the safe transmission of high voltage between the terrestrial electrical switchboard and the top of the drilling rig. In a potentially explosive atmosphere, the 690 V distribution is ensured not only by the durable braiding of the cabling, but also by the spark-proof connectors of the TENEO TEX series, which in all respects exceed the requirements of ATEX certification.

The harness consists of three separate electrical phases and one ground conductor. For a trouble-free placement in the construction of the drilling set, we designed a 46-meter-long bundle: the initial 8 meters of the cable harness are branched into three separate conductors for easy connection to the switchboard, the last meter then forms the end for connecting appliances at the top of the tower. For the final segment, we tailor-made massive stainless steel handles that simply fit into the existing load-bearing structure.

Because it is an installation in a hazardous environment in the mining industry, we have connected TENEO TEX single-pin connectors to both ends of the cable harness. They can transmit up to 990 A / 1,000 V and thus exceed customer requirements by almost 40%. Their spark-resistant construction and fully hermetically sealed connection to the conductor make the TENEO TEX series an ideal solution for gaseous atmospheres with a risk of explosion and for installations with the need for compatibility with established Amphenol or Winchester products.

This cable harness is further proof of our ability to efficiently produce tailor-made solutions that are not only quickly available to the customer, but also cost-effective.

You can see photos from the cable harness assembly in the gallery. A time-lapse video from the final stage of packing and preparing the expedition is below.