SUPROMONT (N)3GHSSHCH 6/35 kV Flexible Medium Voltage Reeling Cable for Tunnel Boring Machines in Underground Mines

The SUPROMONT (N)3GHSSHCH represents a pinnacle of engineering excellence in the field of medium voltage TBM cable technology. This high-performance underground mining reeling cable is specifically engineered to withstand the extreme operating conditions encountered in tunnel boring machine applications and underground mining operations. Designed to deliver reliable power transmission in the harshest environments, this tunnel boring machine power cable incorporates advanced materials and construction techniques to ensure optimal performance, safety, and longevity in demanding subterranean applications.

As infrastructure development and mining operations continue to expand globally, the demand for robust, flexible power solutions has never been greater. The SUPROMONT (N)3GHSSHCH cable addresses these critical needs through its innovative design, combining superior electrical performance with exceptional mechanical durability to support the most challenging tunnel construction and mining projects worldwide.

Product Applications

Primary Applications in Tunnel Boring Operations

The SUPROMONT (N)3GHSSHCH serves as a reeling power supply cable for tunnel boring machines in underground mining operations, where reliability and performance are absolutely critical. These massive machines require continuous, stable power delivery to operate their cutting heads, conveyor systems, and hydraulic mechanisms. The cable's flexible design enables it to wind and unwind smoothly on reel drums as tunnel boring machines advance through rock formations, maintaining consistent electrical connectivity throughout extended boring operations.

In underground mining environments, this medium voltage reeling cable provides essential power distribution to mobile mining equipment including load-haul-dump vehicles, continuous miners, and drilling rigs. The cable's robust construction allows it to withstand the constant flexing, twisting, and mechanical stress associated with equipment movement in confined underground spaces.

Secondary Applications in Tunnel Construction

Beyond mining applications, the SUPROMONT (N)3GHSSHCH excels as a tunnel boring machine cable for civil engineering projects including subway construction, highway tunnels, and water management systems. Major infrastructure projects such as urban transit systems rely on this cable's dependable performance to power tunnel boring machines through varying geological conditions while maintaining strict safety standards.

The cable's versatility extends to semi-fixed installations where power distribution networks require flexible connections between stationary equipment and mobile machinery. This includes applications in underground chambers, ventilation systems, and emergency power distribution networks where environmental conditions demand exceptional cable resilience.

Construction and Materials

Advanced Conductor Design

The SUPROMONT (N)3GHSSHCH features a finely stranded copper conductor manufactured to class 5 specifications, ensuring maximum flexibility while maintaining excellent electrical conductivity. The conductor's fine stranding configuration reduces internal stress during flexing operations, significantly extending cable service life in demanding reeling applications. Each conductor strand is carefully sized and arranged to minimize electrical losses while providing the mechanical flexibility essential for high-frequency bending cycles.

The conductor construction incorporates optimized cross-sectional areas ranging from 25 mm² to 240 mm² to accommodate various power requirements across different tunnel boring machine configurations. This range allows for precise matching of electrical capacity to specific equipment power demands while maintaining optimal cable dimensions for handling and installation.

Superior Insulation System

The cable employs a sophisticated insulation system based on EPR (ethylene propylene rubber) compounds specifically formulated for high-voltage underground applications. This insulation system includes inner and outer semi-conductive layers that ensure uniform electrical field distribution around the conductor, preventing corona discharge and extending insulation life under high-stress conditions.

The EPR rubber insulation demonstrates exceptional resistance to thermal cycling, mechanical deformation, and chemical exposure commonly encountered in mining environments. Semi-conductive NBR (nitrile butadiene rubber) layers provide easy-strip functionality for termination procedures while maintaining electrical integrity under operating conditions.

Robust Outer Sheath and Armor

The SUPROMONT (N)3GHSSHCH incorporates a halogen-free thermoplastic polymer outer sheath that provides outstanding resistance to oils, acids, bases, and mechanical abrasion. This specially formulated compound maintains flexibility across wide temperature ranges while offering superior protection against chemical attack and UV radiation when cables are exposed to mine lighting systems.

Galvanized steel braiding armor provides exceptional mechanical protection and electromagnetic shielding, crucial for reliable operation in electrically noisy underground environments. The armor construction distributes mechanical loads evenly across the cable structure, preventing damage from crushing forces, impacts, and tensile stresses encountered during installation and operation.

Electrical Specifications

Voltage Ratings and Testing Standards

The SUPROMONT (N)3GHSSHCH is available in multiple voltage configurations to meet diverse application requirements. Standard voltage ratings include 6/10 kV, 8.7/15 kV, 12/20 kV, and 20/35 kV, with maximum operating voltages (Um) ranging from 12 kV to 42 kV. These voltage levels accommodate the full spectrum of tunnel boring machine power requirements from auxiliary systems to main drive motors.

Test voltage specifications reach up to 50 kV AC, demonstrating the cable's ability to withstand voltage surges and transient conditions common in industrial power systems. Control cores are tested at 2 kV AC, ensuring reliable operation of monitoring and control circuits essential for safe tunnel boring machine operation.

Current Carrying Capacity

Current carrying capacity varies with conductor cross-section and installation conditions, ranging from 139 amperes for smaller conductors to 574 amperes for the largest configurations. These current ratings are based on continuous operation at maximum conductor temperature while maintaining insulation integrity and mechanical performance.

The cable's electrical parameters include optimized capacitance and inductance values that minimize power losses and improve system efficiency. Conductor resistance values at 20°C range from 0.0801 Ω/km for 240 mm² conductors to 0.795 Ω/km for 25 mm² conductors, ensuring minimal voltage drop over extended cable runs.

Mechanical and Thermal Performance

Temperature Characteristics

The SUPROMONT (N)3GHSSHCH operates reliably across ambient temperatures from -40°C to +80°C for fixed installations and +5°C to +80°C for flexible applications. Maximum conductor temperature reaches 90°C during normal operation, with short-circuit capability extending to 250°C without permanent damage to insulation systems.

These temperature ratings ensure reliable operation in diverse underground environments, from naturally cool deep mines to thermally challenging tunnels with high ambient temperatures due to equipment operation and limited ventilation.

Mechanical Strength and Flexibility

Permanent tensile strength of 15 N/mm² provides exceptional resistance to pulling forces encountered during installation and operation. The cable design accommodates bending radius requirements of 6 × cable diameter for fixed installations and 10 × cable diameter for flexible applications, enabling tight routing in confined underground spaces.

The cable's construction allows for continuous flexing cycles without degradation of electrical or mechanical properties. This flexibility is essential for reeling applications where cables must repeatedly wind and unwind as tunnel boring machines advance through rock formations.

Chemical and Environmental Resistance

Halogen-Free Formulation

The SUPROMONT (N)3GHSSHCH employs halogen-free compounds throughout its construction, eliminating the emission of toxic gases in case of fire. This feature is particularly critical in underground environments where evacuation may be limited and ventilation systems could spread harmful gases throughout tunnel networks.

Flame retardant properties comply with IEC 60332-1-2 standards, providing essential fire safety characteristics for underground installations. The cable's low smoke emission characteristics improve visibility during emergency situations, supporting safe evacuation procedures.

Chemical and UV Resistance

Advanced polymer compounds provide exceptional resistance to oils, acids, bases, and other chemicals commonly encountered in mining and tunnel construction environments. The cable maintains its physical and electrical properties when exposed to hydraulic fluids, cutting oils, and cleaning chemicals used in tunnel boring operations.

UV resistance ensures cable integrity when exposed to high-intensity lighting systems used in underground work areas. Ozone resistance prevents degradation from electrical equipment and welding operations common in tunnel construction environments.

Key Features and Benefits

Enhanced Operational Reliability

The 6/35 kV flexible rubber-insulated reeling cable for TBM applications delivers unmatched reliability through its advanced design and materials selection. The cable's ability to withstand millions of flexing cycles while maintaining electrical integrity ensures continuous tunnel boring operations without costly downtime for cable replacement.

Integrated control cores enable real-time monitoring of cable condition and system performance, allowing operators to implement predictive maintenance strategies that maximize equipment availability and operational efficiency.

Optimized Design for Underground Applications

The medium voltage reeling cable for tunnel boring machines incorporates design features specifically tailored to underground mining requirements. Compact construction reduces space requirements in confined tunnel environments while maintaining full electrical performance capabilities.

Lightweight construction minimizes handling effort during installation and maintenance operations, reducing labor costs and improving worker safety in underground environments where manual handling capabilities may be limited.

Long Service Life

The halogen-free MV reeling cable underground mines application benefits from materials and construction techniques that maximize service life under harsh operating conditions. Advanced insulation compounds resist thermal aging, mechanical wear, and chemical attack, ensuring reliable operation throughout extended project timelines.

The cable's resistance to moisture ingress and contamination maintains electrical integrity in wet underground environments, preventing failures that could compromise tunnel boring operations and worker safety.

Installation and Handling

Recommended Installation Practices

Proper installation of the high-performance TBM power cable for tunnel construction requires attention to cable routing, support systems, and termination procedures. Cable drums should be sized appropriately to maintain minimum bending radius requirements while providing adequate capacity for tunnel length requirements.

Installation teams should utilize proper lifting equipment and cable pulling techniques to prevent damage during deployment. Cable supports must be positioned to prevent sharp edges or abrasive contact that could compromise outer sheath integrity over extended operating periods.

Maintenance and Inspection Protocols

Regular visual inspection of cable exteriors should focus on identifying cuts, abrasion, or deformation that could indicate potential failure points. Electrical testing protocols should include insulation resistance measurements and partial discharge monitoring to detect developing insulation problems before they cause service interruptions.

Proper storage practices for spare cable lengths include protection from moisture, direct sunlight, and chemical contamination. Temperature control during storage ensures that rubber compounds maintain their flexibility and performance characteristics when cables are deployed for service.

Safety and Compliance

International Standards Compliance

The SUPROMONT (N)3GHSSHCH meets rigorous international standards including DIN VDE specifications for electrical parameters and construction requirements. IEC compliance ensures global acceptability for international tunnel construction and mining projects requiring standardized electrical equipment.

Safety Features and Testing

Advanced testing protocols verify cable performance under simulated operating conditions including thermal cycling, mechanical flexing, and electrical stress testing. These comprehensive test procedures ensure that cables will perform reliably throughout their intended service life under actual operating conditions.

Built-in safety features include flame retardant materials, low smoke emission characteristics, and halogen-free construction that minimize risks to personnel in underground environments. These features are particularly important in confined spaces where evacuation options may be limited during emergency situations.

Frequently Asked Questions

Q: What makes this cable suitable for continuous reeling applications in tunnel boring machines?

A: The SUPROMONT (N)3GHSSHCH incorporates several design features specifically for continuous reeling applications. The finely stranded class 5 conductor provides exceptional flexibility while maintaining conductivity. The EPR rubber insulation system resists cracking and degradation during repeated bending cycles. The overall construction includes optimized layer interfaces that minimize internal stress during flexing, enabling millions of flex cycles without electrical or mechanical failure.

Q: How does the cable perform in wet underground environments with high humidity and water exposure?

A: The cable's construction includes moisture barriers and water-resistant compounds throughout the insulation system. The outer sheath provides excellent protection against water ingress, while the semi-conductive layers maintain their electrical properties in high-humidity conditions. The galvanized steel armor provides additional protection against corrosion in wet environments, ensuring long-term reliability even when exposed to groundwater infiltration common in underground mining operations.

Q: What installation considerations are critical for maintaining cable performance and safety?

A: Critical installation factors include maintaining minimum bending radius requirements during routing and drum installation. Proper cable support systems prevent stress concentration at mounting points. Termination procedures must maintain the cable's electrical integrity through proper sealing and stress relief techniques. Environmental protection during installation prevents contamination that could compromise long-term performance. Regular inspection schedules should be established to monitor cable condition throughout its service life.

Q: How does the halogen-free construction impact fire safety in underground tunnels?

A: Halogen-free construction eliminates the production of toxic hydrogen halide gases during combustion, significantly improving safety in confined underground spaces. The flame-retardant properties limit fire spread along cable routes, while low smoke emission characteristics maintain visibility during emergency evacuation procedures. These features are essential in underground environments where ventilation systems could distribute toxic gases throughout tunnel networks, endangering personnel in areas remote from the fire source.

Conclusion

The SUPROMONT (N)3GHSSHCH 6/35 kV flexible medium voltage reeling cable represents the culmination of advanced engineering and materials science applied to the demanding requirements of tunnel boring machine applications and underground mining operations. Its sophisticated construction combines exceptional electrical performance with outstanding mechanical durability, providing reliable power transmission solutions for the world's most challenging subterranean projects.

Through its innovative design incorporating halogen-free materials, advanced insulation systems, and robust mechanical protection, this cable delivers the performance reliability essential for continuous tunnel boring operations while maintaining the highest safety standards for underground personnel. The cable's ability to withstand millions of flexing cycles while maintaining electrical integrity ensures operational continuity critical to project success and economic viability.

For engineers and project managers seeking reliable power solutions for tunnel boring machines and underground mining equipment, the SUPROMONT (N)3GHSSHCH offers proven performance backed by comprehensive testing and international standards compliance. Its versatility across multiple voltage ratings and configurations enables precise matching to specific application requirements while providing the flexibility to accommodate evolving project needs.

Contact qualified cable specialists for detailed technical datasheets and project-specific consultation to optimize cable selection and installation procedures for your tunnel boring or underground mining application.