Located in the Polar Urals, ENISEY drills year-round in temperatures below -45°C. This harsh climate destroyed the drilling rig’s original Chinese power and control cable harnesses in just one winter. Seeking a robust, high-quality replacement, ENISEY required a custom solution due to a lack of technical documentation and incompatible Chinese technology. The new harnesses needed to connect directly to the existing Top Drive and switchboard without costly modifications.

While this non-standard request stopped other suppliers, we accepted the challenge. Despite a 3,700 km distance and communication barriers, we designed, manufactured, tested, and installed 400 meters of custom cable harnesses (weighing over 8 tons) from scratch in just three months. Proving our philosophy that “every problem has a solution,” our holistic approach exceeded the original harnesses’ lifespan by over a thousand times during five years of trouble-free service.

Project Scope & Deliverables:

• Design & Documentation: Created project documentation, 3D models, and prototypes for connectors, harnesses, and components (clamps, holders, hose protectors).

• Laboratory Testing: Verified component and potting compound resistance in extreme Siberian conditions down to -70°C.

• In-House Production: Manufactured connectors, assembled and sealed polyurethane-encapsulated harnesses, and wound bundles onto drums.

• Logistics & Installation: Transported the equipment 3,700 km (including heavy-duty helicopter delivery) followed by on-site assembly, professional wiring, and testing.

MND a.s., a leading Czech oil and gas extraction company operating globally, faced an urgent issue in 2016. A night shift on the Bentec drilling rig near Borkovany (Czech Republic) reported a failure in the auxiliary cable harness leading from the main switchboard to the Top Drive, caused by long-term wear. To minimize economic losses, MND needed a high-quality, rapid, and local solution.

Thanks to our mining industry expertise and status as a direct manufacturer of explosion-proof TEX series EX connectors, MND chose us. We arrived on-site the next day to assess the Bentec rig. The new harness required long-term resistance to aggressive petroleum substances, rough handling, and strict EX certification for explosive environments.

We immediately processed the project documentation and delivered a custom drawing. The complete EX cable harness in the AUX-SERVICE-LOOP design was manufactured at our North Bohemian factory and delivered in less than 2 months. This initial emergency response established a long-term partnership, and our harness has been operating flawlessly for over 4 years.

Project Scope & Deliverables:

• Assessment & Design: Measured the site, proposed compatible solutions, checked provided documentation, and created a custom harness drawing.

• Material Selection: Selected specialized cables and hoses suited for specific climatic conditions.

• In-House Production: Manufactured TEX series connectors, stainless steel hose endings, and stainless steel harness holders.

• Harness Assembly: Pulled cables through hoses, fitted holders/endings, applied potting compound, and wired all connectors.

• Finishing & Logistics: Fitted free ends with a spiral braid (secured via adhesive shrink tubes), wound the harness onto a wooden drum, and secured it for transport.