Power Meets Intelligence: Why (N)TSCGEWOEU Medium Voltage Reeling Cables with Fibre Optics Are Redefining Heavy Industry in South Africa

Introduction

Why Medium Voltage Reeling Cables Matter in South Africa

South Africa’s heavy industries operate at a scale and intensity that few regions in the world can match. From the vast open-cast coal mines of Mpumalanga, to the iron ore operations in the Northern Cape, and the high-throughput ports of Richards Bay and Saldanha Bay, mobile machinery forms the backbone of daily production.

Unlike fixed installations, these environments rely heavily on large mobile electrical equipment, including:

• Bucket wheel excavators (BWEs)

• Spreaders and stacker-reclaimers

• Gantry cranes and ship loaders

• Rail-mounted and rubber-tyred bulk handling systems

These machines demand continuous medium voltage power while moving over long distances, often under some of the harshest mechanical and environmental conditions on the planet.

This is where medium voltage reeling cables become mission-critical components rather than passive accessories.

In South Africa, reeling cables must simultaneously withstand:

• Continuous reeling and unreeling cycles

• High tensile and torsional stress

• Abrasion from coal, iron ore, and sand

• Oil, grease, chemicals, and moisture

• High ambient temperatures and UV exposure

• Increasing demand for real-time data transmission and automation

Traditional power-only cables are no longer sufficient. Modern operations require power, control, and data delivered through a single, robust umbilical. This demand has driven the adoption of (N)TSCGEWOEU medium voltage reeling cables with integrated fibre optics across South Africa’s most demanding applications.

What Is the (N)TSCGEWOEU Medium Voltage Reeling Cable with Fibre Optics?

The (N)TSCGEWOEU cable is a heavy-duty medium voltage reeling cable designed specifically for dynamic applications under extreme mechanical loads, where continuous movement, torsion, and high electrical performance are unavoidable.

What sets this cable apart is its hybrid design, combining:

• Medium voltage power transmission

• Integrated fibre optic communication

in a single, mechanically reinforced cable construction.

Typical voltage classes include:

• 3.6/6 kV

• 6/10 kV

• 12/20 kV

• 18/30 kV

This makes the (N)TSCGEWOEU suitable for both legacy mining systems and modern high-power, digitally connected equipment.

In simple terms, this cable does not just power machines—it enables smart, data-driven operations, aligning perfectly with South Africa’s gradual shift toward automation, condition monitoring, and Industry 4.0 principles.

Typical Applications

Heavy Mobile Equipment Under Extreme Mechanical Loads

The primary application domain of the (N)TSCGEWOEU medium voltage reeling cable is large mobile equipment operating under continuous dynamic stress.

Typical machines include:

• Excavators and bucket wheel excavators used in open-cast mining

• Spreaders handling overburden removal

• Stacker-reclaimers in coal, iron ore, and manganese stockyards

• Gantry cranes and ship loaders in ports

• Rail-mounted and rubber-tyred bulk handling equipment

In these applications, cables are not static assets. They are mechanically active components subjected to bending, twisting, and pulling every minute of operation.

Motorised Reeling Systems

(N)TSCGEWOEU cables are engineered specifically for motorised reeling systems, including:

• Monospiral reelers

• Level-wind reelers

These systems impose:

• Continuous dynamic bending

• Alternating torsional loads

• High tensile forces during acceleration and braking

Without proper anti-torsion reinforcement and flexible conductor design, conventional cables fail prematurely through conductor fatigue, insulation cracking, or sheath damage.

South African Industry Focus

The adoption of fibre-integrated medium voltage reeling cables is particularly strong in:

• Mpumalanga – open-cast coal mines with long travel distances

• Northern Cape – iron ore operations requiring high power levels

• Richards Bay – coal export terminals with automated stacker-reclaimers

• Saldanha Bay – iron ore port operations exposed to salt air and wind

These regions represent some of the most mechanically and electrically demanding cable environments in the country.

Applicable Standards and Compliance

International Design Basis – VDE 0250 Part 813

The (N)TSCGEWOEU cable is designed based on VDE 0250 Part 813, a German standard globally recognised for heavy-duty reeling and trailing cables.

German engineering standards are widely respected in South African mining due to their emphasis on:

• Mechanical endurance

• Electrical reliability

• Long service life under dynamic stress

This design basis ensures that the cable meets international best practice for reeling applications.

Alignment with South African Requirements

While VDE provides the design framework, practical deployment in South Africa requires alignment with:

• SANS cable performance expectations

• Mine Health and Safety Act (MHSA) principles

Key considerations include:

• Flame retardancy in underground and surface installations

• Oil and chemical resistance

• Robust earthing design for fault protection

(N)TSCGEWOEU cables are widely accepted in South African operations because they meet or exceed local safety and performance expectations, even when not governed by a single mandatory national standard.

Cable Construction Overview

Conductor Design

At the core of the cable are flexible stranded copper conductors, classified as Class 5 according to DIN VDE 0295.

This high strand count provides:

• Superior flexibility

• Reduced stress concentration during bending

• Improved fatigue resistance under dynamic movement

For reeling applications, conductor flexibility is not optional—it is essential for long service life.

Inner Semiconductive Conductor Layer

Each conductor is surrounded by a semiconductive inner layer, which plays a critical role in:

• Controlling the electric field

• Minimising partial discharge

• Ensuring uniform stress distribution

In medium voltage systems, unmanaged electric stress can dramatically shorten insulation life, especially under mechanical movement.

Insulation System – EPR Type 3GI3

The insulation material is EPR (Ethylene Propylene Rubber), Type 3GI3.

EPR is widely preferred in reeling cables because it offers:

• Excellent thermal stability

• High dielectric strength

• Outstanding flexibility

• Resistance to cracking under cyclic mechanical stress

Compared to XLPE, EPR maintains elasticity over a wider temperature range—an important advantage in South Africa’s variable climate.

Outer Semiconductive Layer

An outer semiconductive layer ensures:

• Uniform electric field distribution

• Improved long-term insulation reliability

• Reduced risk of partial discharge at interfaces

This layered insulation system is essential for medium voltage dynamic applications.

Earth Conductor Design

The earth conductor is split into two separate conductors, positioned in the outer interstices.

This design provides:

• Balanced fault current paths

• Enhanced mechanical symmetry

• Improved safety during earth faults

It is a proven configuration in heavy-duty mining cables.

Inner Sheath

The inner sheath is made from rubber type GM1b / 5GM3, providing:

• Mechanical cushioning

• Core protection against movement

• A stable base for reinforcement layers

Integrated Fibre Optics System

Fibre Optic Configuration

The cable integrates 12 fibre optic elements, housed within a dedicated protective sheath.

Available fibre types include:

• 50/125 µm

• 62.5/125 µm

• E9/125 µm

These fibres are mechanically isolated from the power cores, ensuring reliable performance even under continuous reeling.

Role of Fibre Optics in Modern Mining

In modern South African operations, fibre optics enable:

• Real-time equipment monitoring

• High-speed data transmission

• Control system integration

• Predictive maintenance strategies

By embedding fibres directly into the power cable, operators eliminate the need for separate data cables—reducing failure points and simplifying cable management.

Benefits for South African Operations

The integration of fibre optics delivers measurable operational benefits:

• Reduced unplanned downtime

• Faster fault diagnosis

• Improved asset utilisation

• Support for smart mining initiatives

For operations working on tight production margins, these advantages translate directly into cost savings.

Mechanical Reinforcement and Outer Sheath

Polyester Anti-Torsion Braid

A polyester anti-torsion braid is incorporated as a reinforcement layer.

Its function includes:

• Absorbing torsional forces

• Preventing conductor twisting

• Maintaining cable geometry under load

This feature is critical for long travel distances and heavy reels.

Outer Sheath Design

The outer sheath is manufactured from rubber type 5GM3 / 5GM5, offering:

• Flame retardancy

• Oil and chemical resistance

• High abrasion resistance

• Suitability for harsh African climates

This sheath protects the cable against coal dust, iron ore fines, oils, UV radiation, and mechanical impact.

Electrical and Technical Parameters

Voltage Ratings

(N)TSCGEWOEU cables are available in:

• 3.6/6 kV

• 6/10 kV

• 12/20 kV

• 18/30 kV

This wide range supports both existing installations and future power upgrades.

Core Configurations

A typical configuration includes:

• 3 power cores

• 2 earth conductors

• 12 fibre optics

This structure balances electrical performance, safety, and communication capability.

Dimensional and Weight Considerations

Overall diameter and weight vary with voltage class and conductor size, ranging from approximately 39 mm to 90 mm in diameter and 2,400 kg/km to over 12,500 kg/km.

Accurate dimensional data is essential for:

• Reel sizing

• Drive torque calculation

• Mechanical system design

Installation and Operational Considerations

Reeling and Unreeling Behaviour

Correct installation practices include:

• Observing minimum bending radius

• Avoiding reverse torsion

• Ensuring correct reel alignment

Poor installation can negate even the best cable design.

Environmental Factors in South Africa

South African conditions present unique challenges:

• High ambient temperatures

• Dust and abrasive materials

• Oil contamination

• UV exposure in open-cast mines

(N)TSCGEWOEU cables are engineered specifically to handle these factors.

South African Case

Open-Cast Coal Mine in Mpumalanga

Application: Bucket wheel excavator reeling system
Cable: 6/10 kV (N)TSCGEWOEU with fibre optics

Challenges:

• Long travel distances

• High torsional loads

• Need for real-time machine monitoring

Performance Results

After installation:

• Cable service life increased significantly

• Unplanned downtime reduced

• Real-time data enabled proactive maintenance

This case clearly demonstrates the value of fibre-integrated reeling cables in South African mining.

Comparison with Conventional Reeling Cables

Compared to power-only cables, fibre-integrated designs offer:

• Lower total cost of ownership

• Improved operational visibility

• Reduced auxiliary cabling

Over the cable’s life cycle, the benefits far outweigh the initial investment.

Common Problems and Solutions

Mechanical Failures

• Torsion fatigue

• Sheath abrasion

Electrical Issues

• Partial discharge

• Insulation ageing

How (N)TSCGEWOEU Addresses These Challenges

• Anti-torsion braid

• EPR insulation

• Semiconductive layers

Frequently Asked Questions (FAQ)

What makes (N)TSCGEWOEU suitable for heavy reeling?
Its flexible conductors, anti-torsion reinforcement, and robust insulation system.

Why EPR over XLPE?
Better flexibility and crack resistance under dynamic stress.

Can fibre optics survive reeling?
Yes, when properly protected and integrated.

Is it suitable for ports and mines?
Absolutely—this versatility is one of its key strengths.

Conclusion

In South Africa’s demanding mining, port, and industrial environments, cable selection is a strategic engineering decision, not a commodity purchase.

(N)TSCGEWOEU medium voltage reeling cables with fibre optics offer:

• Proven mechanical durability

• Reliable medium voltage performance

• Built-in intelligence for modern operations

For operators seeking future-ready, high-reliability solutions, these cables represent a clear and compelling choice.