Ocean Cable Engineering Handbook-Vol9 Compiled by Ian S. Coote

Ocean
Engineering Notes.
Compiled
by
Ian S. Coote
Part 3
Handbook
for
Ocean Cable Engineering.
Volume 9
System
Maintenance.
1st. Edition
This compilation
Copyright 2009 by Ian S. Coote.
Neither Ian S. Coote, or any of his associates

makes any warranty, express or implied,
or assumes any legal liability or responsibility
for the accuracy, completeness or usefulness of
any information, apparatus, product or process
disclosed, or represents that its use would not
infringe privately-owned rights.
Page i
Contents.
Page No.
1. Introduction. 1
2. Inspection. 2
2.1 General. 2
2.2 Inspection by Divers. 2
2.2.1 Overview. 2
2.2.2 Priorities. 2
2.2.3 Inspection Method. 3
2.2.3.1 General. 3
2.2.3.2 Shore Inspection. 3
2.2.3.2.1 New Benchmarks. 3
2.2.3.2.2 Existing Benchmarks. 4
2.2.3.3 Underwater Inspection. 4
2.2.3.3.1 Overview. 4
2.2.3.3.2 Establishing Stations - Ocean Cable Visible. 4
2.2.3.3.3 Cable Buried in Bottom. 5
2.2.3.3.4 Positioning Method. 5
2.2.4 Ocean Cable Condition. 7
2.2.5 Sensor Unit Condition. 10
2.3 Inspection by ROVs. 10
2.4 Inspection by Side Scan Sonar. 10
3. Repair. 11
3.1 Fault Location. 11

3.1.1 Overview. 11
3.1.2 Fault Location from Shore Stations. 11
3.1.2.1 Repeatered Coaxial Ocean Cable Systems. 11
3.1.2.2 Repeatered Optical Ocean Cable Systems. 12
3.1.2.3 Repeatered Multiconductor Ocean Cable Systems. 13
3.1.2.4 Unrepeatered Ocean Cable Systems. 13
3.1.3 Fault Location from the Cable Ship. 13
3.1.3.1 Underway. 13
3.1.3.2 Cable Ends Onboard. 15
3.2 Repair Operations. 15
3.2.1 Overview. 15
3.2.2 Repair Methods. 16
3.2.2.1 General Comments. 16
3.2.2.2 Procedure Using Grappling. 17
3.2.2.3 Procedure Using Cable Repair ROVs. 17
3.2.2.4 Procedure for Arrays. 18
3.2.2.4.1 Nearshore Arrays. 18
3.2.2.4.2 Offshore Arrays. 19
Page ii
Contents ( Continued ).
Page No.
4. Jointing and Splicing Ocean Cables. 21
4.1 Introduction. 21
4.2 Jointing Conductors. 21
4.2.1 Overview. 21
4.2.2 Equipment. 21
4.2.2.1 General. 21
4.2.2.2 General. 21
4.2.2.2.1 Swaging Tool - Small Conductors. 21
4.2.2.2.1.1 Description. 21
4.2.2.2.1.2 Usage. 22
4.2.2.2.1.3 Qualification. 22
4.2.2.2.2 Conductor Brazing Machine. 22
4.2.2.2.2.2 Usage. 24
4.2.2.2.3 Swaging Press for Center Strength Member Ocean Cables. 27
4.2.2.2.3.2 Usage. 28
4.2.2.3 Injection Molding Machines. 30
4.2.2.3.1 Description. 30
4.2.2.3.2 Usage. 36
4.2.2.3.3 Qualification. 36
4.2.2.4 Return Tape Jointing Equipment. 37
4.2.2.4.1 Brazing. 37
4.2.2.4.1.2 Usage. 38
4.2.2.4.2 Cold Pressure Welding. 38
4.2.2.4.2.2 Usage. 39
4.2.2.5 Fusion Splicer for Optical Fibers. 39
4.2.2.5.2 Usage. 40
4.2.2.6 X-ray Cameras. 40
4.2.2.6.2 Usage. 43
4.2.2.6.3 Qualification. 43
4.2.3 Procedures for Making Conductor Joints. 43
4.2.3.1 Classification. 43
4.2.3.2 Jointing Small Electrical Conductors. 45
4.2.3.2.1 Introduction. 45
4.2.3.2.2 Equipment. 45
4.2.3.2.3 Procedure. 45
Page iii
Contents ( Continued ).
Page No.
4.2.3.3 Jointing Large Electrical Conductors. 49

4.2.3.3.2 Equipment. 49
4.2.3.3.3 Procedure. 50
4.2.3.4 Jointing Optical Conductors. 61
4.2.3.4,2 Equipment. 61
4.2.3.4.3 Procedure. 61
4.3 Splicing Armor Wires. 66
4.3.1 Overlaid Splice. 66
4.3.1.1 Introduction. 66
4.3.1.2 Equipment. 66
4.3.1.3 Procedure. 68
4.3.2 Ring Splice. 79
4.3.2.1 Introduction. 79
4.3.2.2 Equipment. 81
4.3.2.3 Procedure. 82
4.4 Times to CarryOut Jointing and Splicing of Ocean Cables. 90
Annexes.
A. Electromagnetic Field Around Ocean Cables. A1
A.1 Overview. A1
A.2 Wave-guide Analysis for Symmetric Ocean Cable. A1
A.3 Transmission Line Analysis. A3
B. Cable Repair ROVs. A7
B.1 Introduction. A7
B.2 Cable Repair ROVs in Service. A7
B.3 Description of Cable Repair ROVs. A8
B.3.1 SCARAB. A8
B.3.1.1 Development. A8
B.3.1.2 Characteristics. A9
B.3.2 CIRRUS. A12
B.3.3 Cable Repair System ( CRS ). A14
B.4 Operation of Cable Repair ROVs. A17
B.4.1 General. A17
B.4.2 Operator Displays and Controls. A17
B.4.3 Operation of the Vehicle/ A18
B.5 Notes on ROV Characteristics A24
Page iv
Figures.
Page No.
2.2.3.3.2(a) Search method. 5
2.2.3.3.4(a) Triangulation cable survey method. 7
3.1.2.2(a) Diagram of loop back system in repeaters. 13
3.1.3.1(a) Trailed electrode ocean cable and fault location method. 14
3.1.3.1(b) Towed induction coil ocean cable and fault location 15

method.
4.2.2.2.1.2(a) Swaging sleeve onto conductors. 22
4.2.2.2.2.1(a) Portable brazing machine. 23
4.2.2.2.2.1(b) Circuit diagram - portable brazing machine. 24
4.2.2.2.2.2(a) Arrangement for brazing central conductor. 25
4.2.2.2.2.2(b) Arrangement for tinning one end of a stranded or 25

composite center conductor.
4.2.2.2.2.2(c) Arrangement for welding mild steel cores of 26

4.2.2.2.2.2(d) Arrangement for brazing ferrule on mild steel core 26

4.2.2.2.2.2(e) Arrangement for burning through high-tensile steel 27

cored center conductor.
4.2.2.2.3.1(a) Swaging press for jointing center strength member. 28
4.2.2.2.3.2(a) Steps in swaging ferrule on center strength member 29

( coaxial cable ).
4.2.2.3.1(a) Injection molding machine, spring feed type, single 30

load, shown without cable clamps ( STC type ).
4.2.2.3.1(b) Injection molding machine, spring feed type, shown 31

without interchangeable molds and cable clamps
( SCANTI No. 2 type ).
4.2.2.3.1(c) Pneumatically driven feed molding machine with 32

automatic temperature control, single mold and
clamps ( WECo type ).
Page v
Figures ( Continued ).
Page No.
4.2.2.3.1(d) Basic components of air driven injection molding 33

machine.
4.2.2.3.1(e) Injection machine mold for quad cable ( WECo type ). 34
4.2.2.3.1(f) Injection machine mold for dielectric of coaxial cable 35

( SCANTI ).
4.2.2.4.1.1(a) Transformer unit for brazing return tapes. 38
4.2.2.4.2.1(a) Cold pressure welding tool for return tapes. 39
4.2.2.5.1(a) Fusion splicer for UC/UJ technology ( Universal 40

Jointing Consortium ).
4.2.2.6.1(a) Portable X-ray machine. 41
4.2.2.6.1(b) Cable clamp on X-ray machine exposure head. 42
4.2.2.6.1(c) X-ray camera type 13 M. III for UC/UJ technology 42

( Universal Jointing Consortium ).
4.2.3.2.1(a) Joint on 0.051/0.180 conductor. 44
4.2.3.2.3(a) Arrangement for cutting quads and conductors to 46

give staggered joint ( 4 quad cable shown ).
4.2.3.2.3(b) Arrangement of jointing table for multi-conductor 48

ocean cables.
4.2.3.3.3(a) Preparation of coaxial cable end for jointing. 51
4.2.3.3.3(b) Joining center conductors of coaxial ocean cable. 53
4.2.3.3.3(c) Arrangement of jointing table for coaxial ocean cables. 54
4.2.3.3.3(d) Joining multiple helically applied return tapes. 56
4.2.3.3.3(e) Joining single longitudinal return tapes. 58
4.2.3.3.3(f) Sheath restoration. 60
4.2.3.4.3(a) Basic components of Universal Jointing Kit. 62
4.2.3.4.3(b) Universal Joint ready for overmolding to restore 63

insulation.
Page vi
Page No.
4.2.3.4.3(c) Completed Universal Joint after insulation restored 64

with sprues from molding process.
4.2.3.4.3(d) Deep sea cable splice. 65
4.2.3.4.3(e) Armored cable splice ( Alcatel-Lucent ). 65
4.3.1.2(a) Splicing tool for overlaid splice ( Two required, one 67

for short end armor, and one for long end armor ).
4.3.1.3(a) Preparation of cable for splicing. 69
4.3.1.3(b) Preparation of cores for jointing. 69
4.3.1.3(c) Jointing core. 71
4.3.1.3(d) Rewinding armor bedding over core. 71
4.3.1.3(e) Rewinding short end armor wires. 73
4.3.1.3(f) Short end armor wires rewound over core. 73
4.3.1.3(g) Rewinding long end armor wires. 75
4.3.1.3(h) Long end armor wires rewound over short end. 75
4.3.1.3(i) Application of outer servings. 77
4.3.1.3(j) Completed splice. 77
4.3.2.1(a) Completed ring splice. 80
4.3.2.3(a) Preparation of cables for splicing. 83
4.3.2.3(b) Preparation of cores for jointing. 83
4.3.2.3(c) Jointing core. 85
4.3.2.3(d) Preparation of first end armor wires. 85
4.3.2.3(e) First end armor wires completed. 87
4.3.2.3(f) Preparation of second end armor wires. 87
4.3.2.3(g) Second end armor wires completed. 89
4.3.2.3(h) Completed splice. 89

Page vii
Page No.
A.3(a) Typical equivalent circuit for coaxial repeater. A4
A.3(b) Propagation of 25 Hz signal, unarmored SG ocean cable A5

with cable breaks at various locations. Center conductor
current 200 mA at shore point, repeaters unpowered.
A.3(c) Propagation of 25 Hz signal, unarmored SG ocean cable A6

with cable breaks at various locations. Center conductor
current 200 mA at shore point, repeaters powered.
B.3.1.2(a) SCARAB I vehicle. A9
B.3.1.2(b) SCARAB IV ROV on launch-and-recover knuckleboom A12

crane.
B.3.2.2(a) CIRRUS vehicle. A14
B.3.3.2(a) Cable Repair System ( CRS ), showing vehicle and tether A16
management system ( TMS ).
B.4.2(a) First display format. A17
B.4.2(b) Second display format. A18
B.4.3(a) Unburying ocean cable using dredger jet. A19
B.4.3(b) Cutting ocean cable. A20
B.4.3(c) Placing clamps on ocean cable. A21
B.4.3(d) Attaching lift line to clamp. A22
B.4.3(e) Re-burying ocean cable. A23

Page viii
Tables.
Page No.
2.2.4(a) Matrix of Observations Cable Inspection Survey - 8

Observation of Condition of Ocean Cable System.
2.2.4(b) Measurements Required. 9
4.2.2.3.3(a) Core Flex Test Bending Radii. 37
A.2(a) Values for Use in Wave-guide Analysis of Ocean Cables. A2
A.2(b) Values for Use in Wave-guide Analysis of Ocean Cables. A3
B.2(a) Characteristics of Some Cable Repair ROVs. A8
B.3.1.2(a) SCARAB I & II Characteristics. A10
B.3.1.2(b) SCARAB IV Characteristics. A11
B.3.2.2(a) CIRRUS Characteristics. A13
B.3.3.2(a) CRS I & II Characteristics. A15

Page ix
Sources of Material Used.
The following are the identifiable sources from which the material used in this volume has
been derived.
Chapters, Sections.
IEE - Submarine Telecommunication Systems, International 3.1.2, 3.1.3, 3.2.2

Conference, 1980, publication.
Bell System Technical Journal, Vol 60,No. 4, April 1981. 3.1.3.1, A, B.3.1, B.4
Oceanographic Cable Inspection Procedures. USN, 1985.. 2.2.3
Cable Repair Ship - T - ARC ( www.fas.org ) B.3.3
AT&T, June 9, 1992 release. B.4
Subsea Cable Location/Fault Isolation System, pp 15-18 3.1.3

Sea Technology, July 1991.
An Update on Transpacific Cable ( Powerpoint Presentation ). 3.1.2.2
ALCATEL OAL repeaters brochure. 3.1.2.2
Universal Jointing Consortium Bulletin Number: UJCB008 4.2.2.5
Universal Jointing Consortium Bulletin Number: UJCB006 4.2.2.6
Universal Jointing Consortium. 4.2.3.4
ROVs for Subsea Cable Maintenance, pp 70-75, Sea Technology, B.2, B.3.1
April 1998.
SCARAB IV: New Design ROV for Cable Installation, Repair, B.3.1
pp 77-80, Sea Technology, April 1991.
BPO Telecommunications Instructions. 4.2
BPO Operating and Maintenance Instructions. 4.2
Alcatel, OALC-7 Type 50 and Type 51 Submarine Cables, 4.2.3.4.3

April 2001.
Page x
Page 1
1. Introduction.
This part of the handbook contains descriptions of various methods used for system
maintenance. After the installation of an ocean cable system is complete, the work on the
system changes to system maintenance. Those components in the terminal building and on the
shore generally present no special problems. The underwater components normally require
maintenance only if failure occurs, or is likely to occur, as these components are usually
designed and constructed for a long life.
Methods described include: the inspection of underwater components, which can be considered
as preventative maintenance; repair techniques, required either to prevent a failure occurring
( such as determined from an inspection ) or to rectify a failure; and cable splicing, required
most times in repair operations.
The electromagnetic field around ocean cables with test signal, and the characteristics and
operation of cable repair ROVs, are described in the annexes.
The other parts of the handbook that support this part of the handbook are:
i) Volume 2 - Cable Laying and Recovery Calculations.
ii) Volume 4 - Grapnels, Grappling and Cable Buoys.
iii) Volume 5 - Rigging Procedures and Cable Stoppers for Working Ocean Cables.
Page 2
2. Inspection.
This chapter describes methods used for the inspection of ocean cable systems.
2.1 General.
This chapter presents methods for the inspection of ocean cables and underwater components
that have proven effective. For shallow water, with depths up to 100 feet - 30 meters and where
the current speed is low, divers are effective, as are smaller ROVs. For higher current speeds,
it will be necessary to use ROVs with more powerful thrusters. In deeper waters, ROVs are
used, though manned submersibles can be used if available. Where visibility is poor, non-
visual sensors becomes necessary on ROVs.
Inspection of the underwater components at regular intervals should be considered if the

components are situated in areas where wear from forces such as surge or currents and damage
to components from activities such as bottom trawling is likely.
Side scan sonar can also be used for inspection of the bottom along the cable route for changes
that may cause cable or component damage.
From the results of an inspection, the need for planning repair or replacement operations can
be determined, to prevent failures occurring at a critical time.
2.2 Inspection by Divers.
2.2.1 Overview.
This section presents the required data and suggested method for inspection of ocean cables
and components by divers.
2.2.2 Priorities.
The customer normally provides specific goals for an inspection. In priority order, they
normally are:
i) Visual inspection and damage report.
ii) Cable track survey ( including component/sensor positions, if applicable ).
iii) Photographs of condition of cable and components, including any damage.
iv) Onsite support information.
v) Shore panoramas, and
vi) Underwater photographs.

Page 3
2.2.3 Inspection Method.
2.2.3.1 General.
The determination of the location of the ocean cable and components ( such as sensors ) is
second only in importance to the visual inspection of the ocean cable ( and components ).
Therefore, both the land and underwater portions of the inspection must be done accurately.
This normally means using Differential GPS for positioning, though triangulation by electronic
distance measuring equipment ( EDM ) can be used for parts of the route close to the shore.
2.2.3.2 Shore Inspection.
2.2.3.2.1 New Benchmarks.
For electronic distance measuring equipment ( EDM ), sufficient benchmarks should be

established such that all of the cable route out to a depth of at least 100 feet - 30 meters is
visible from two benchmarks.
In most cases, this can be done with two positions. Benchmark locations should be determined
by the inspection OIC with the following points in mind:
i) Visibility of the cable track from the position.
ii) Distance from other benchmarks ( needs to be great enough for triangulation, approxi-
mately 0.75 n. miles ), and
iii) Accessibility of position during different weather and tide conditions.
If it is necessary to install a base station for Differential GPS, then only one mark is required,
with line of sight over the cable route to ensure that its signal is not blocked.
The following method should be used to establish new benchmarks:
i) On Rock - Mark locations with a 6 inch by 6 inch - 50 mm by 150 mm metal plate

( stainless steel, brass or bronze ). An engraved X in the center of the plate will mark
the exact location of the benchmark. Plates should have the date on which it was
installed and an identifying letter or number engraved on it, along with the words "For
Information Call xxx-xxxxxxx". The plate may be fastened to the rock using small
rock bolts ( 3/8 inch by 6 inch - 9 mm by 150 mm ) after suitable holes are drilled in
the rock using a hand star drill. An alternative method is to use lead masonry anchors
driven into holes drilled into the rock. The plate could then be secured by standard hex
bolts.
ii) On Soil - Mark location with a steel stake driven 3 to 4 feet - 1 to 1.2 meters into the
ground. An 8 to 10 inch - 200 to 250 mm diameter concrete pad, 18 inches - 450 mm
deep, should be poured around the stake to ensure the position is securely marked.
Stakes should protrude 2 to 3 inches - 50 to 75 mm above the ground level. A metal
plate as described above, placed in a concrete base is also sufficient.
iii) In Sand - No benchmarks should be placed in sand due to the instability of the
position and the fact that drifting sand may cover even a permanently placed mark.
After the benchmarks have been physically constructed, their position must be determined as
detailed in the following section.
Page 4
2.2.3.2.2 Existing Benchmarks.
If the site has been previously inspected, permanent benchmark(s) should have already been
established. In this case, they should be checked to see that they are still in good condition
and still provide the required range of visibility. If so, then all that is required is to confirm
their position(s).
For triangulation by electronic distance measuring equipment ( EDM ), the position is

determined using triangulation with the theodolite set on one point and the transit on the
other. The two instruments should be set on permanent fixed points easily seen and returned
to. From each point, the surveyor must see both the other point and the benchmark in question.
The fixed points to be used, in order of preference are:
i) Geodetic survey marks.
ii) Specific corner of the terminal building; e.g. "2 feet north of the northeast corner of
the terminal building", and
iii) Specific portion of large permanent object; e.g., "2 meters south of the southern leg of
antenna No. 3".
When the instruments are set up on any two points, right angles should be turned to the
benchmark using the line between as a baseline. A distance measurement will also need to be
taken using the EDM unit from one point to the benchmark and between the two points.
This should be repeated for all benchmarks.
For Differential GPS, the base station will normally resurvey the benchmark as part of its
setting up.
2.2.3.3 Underwater Inspection.
2.2.3.3.1 Overview.
The goal of the underwater inspection is to determine the position and depth of the ocean cable
at 100 foot - 30 meters intervals and be able to relate these charted positions back to the cable.
The ocean cable is inspected using the standard method of placing a tethered float at these
intervals along the cable track and using a boat, come up to the float, either triangulating on
the float from the shore or getting its position using Differential GPS. The float is placed
initially at 100 foot - 30 meters intervals if practicable out to a depth of 100 feet - 30 meters (
or a sensor unit ). The interval and depth figures are provided as guidance. If the total cable
length out to 100 foot - 30 meters depth ( or a sensor unit ) is extremely long, then the interval
may be increased. If there is reason to believe that damage may be occurring to the ocean cable
in greater depths, then that area of the cable should be inspected, if possible.
2.2.3.3.2 Establishing Stations - Ocean Cable Visible.
In all portions of the track where the ocean cable is visible, a permanent brass tag should be
placed at each of the 100 foot - 30 meter stations. These tags, normally supplied by the
customer, should have an identifying number or letters.
Along with attaching the tags at each station, a reading of the depth, bottom type, and water
visibility are recorded. The depth reading can be taken with a depth gauge placed on top of the
ocean cable. This information is numbered and recorded on a slate provided for this purpose.
Page 5
Should the ocean cable be more than 3 feet - 1 meter off the bottom, both the bottom depth and
the cable depth are recorded.
The exact method of interval determination is left up to the inspection OIC, as long as they
meet the criteria of every 100 feet - 30 meters. The following method has been found practical.
Intervals are established and marked first by using a 10 foot - 3 meter searching line. Divers
stretch out the line and "leap frog" past each other as shown in figure 2.2.3.3.2(a). This allows
the divers to stay within a safe distance at all times. At each station, the divers join together to
attach the tag, and take, and record the required data. After all the tags are attached, the
divers then return and assist in determining the position of the points.
Note: The lead diver, who leaves the

original tag last, is the first
diver at the new position with
the 10 foot (or 3 meter) line
New tag at
Tag original new station
station
Lead diver Diver No. 2

10 foot
(or 3 meter)
search line
Fig. 2.2.3.3.2(a) Search method.
2.2.3.3.3 Cable Buried in Bottom.
If the ocean cable appears to be buried in the bottom for its entire length, the assumed path of
the cable is searched out to a depth of at least 60 feet - 20 meters. This is done to see if the
cable appears at some short lengths at certain spots. If the cable appears, its position is
surveyed in, and the standard depth/visibility information taken. If the cable does not appears
the area which was searched and the search method should be noted. The bottom type and slope
should also be noted. An underwater cable locator instrument should be used as much as
possible to locate the buried cable.
It should be noted that in cases where the ocean cable is buried only 6 inches - 150 mm or less
below the bottom, its path may be followed by probing the bottom with a suitable rod.
2.2.3.3.4 Positioning Method.
After the tags have been attached ( or in the case of a totally buried cables after the divers are
in position over it ), the positions of each station and object of interest must be surveyed in.
This is done in one of two ways, either using Differential GPS, or a theodolite/EDM unit with a
transit to double check the reading.
Page 6
The theodolite/EDM unit is to be used, it is set up on a previously established land benchmark

and will give an angle and a distance, enough to locate the float. The transit is set up on a
second benchmark and gives an angle for each float. A small boat, such as a Zodiac, must assist
the surveyors as the Differential GPS unit, or a special reflective EDM target, must be
positioned over the buoy.
A dive team is deployed towing a single float with enough line to reach the surface at the
deepest depth. At each previously tagged station, the divers stop, plum the float, and give a
previously established signals such as four pulls on the float. The Zodiac team then runs up
and either takes a Differential GPS reading, or holds the EDM target over the float. They then
report over the radio the Differential GPS position, or that the EDM target is ready for siting
and call out the number of the station. They hold this position until the position of the site is
confirmed. When shore crew(s) report they have the site, they repeat the station number to
avoid confusion. The Zodiac team then signals the divers to proceed to the next station by
tugging on the float.
This procedure should also be repeated at positions of notable cable damage, as noted in
section 2.3.3.
The OIC should check to ensure that the number of points sited by the surveyors is EXACTLY
the same number of points previously marked by the divers on the slate. If not, then the
procedure must be repeated. That is, if the divers marked 52 tags plus one armor damaged
point on the slate for a total of 53 points to be surveyed, then the surveyors must site 53
points. If only 51 points are sited, then there is no way to determine which points were missed.
The triangulation method using the theodolite/EDM and transit is shown in figure 2.2.3.3.4(a).
Note that all angles are right turned angles. Both the transit and the theodolite use the line
between them as a baseline. If they cannot use this baseline for some reason, it should be
specifically noted in the inspection data.
All data is entered on a standard form showing:
a) System used for surveying, and benchmarks used, if applicable.
b) Site number and object. e.g. tag number or cable damage.
c) Position of site, either Differential GPS reading, or theodolite/EDM angle and distance and
transit angle.
d) Depth of site, bottom type, and visibility,
e) Any comments.
Data should be plotted BEFORE LEAVING THE SITE to ensure that it is accurate. Should the
information from the Differential GPS or the theodolite/EDM unit and the transit, appear
wrong, that portion of the inspection will have to be repeated.
Page 7
Out to 100 foot (30 meter) depth
16
15
100 foot (30 meter)
14
13
Small boat and
EDM target 12
Cable buried 11
10
9
Dive team
8
holds float
!1
Broken 7 over station BMA
armor wires
also surveyed 6 Theodolite
5 EDM unit
!2 4
3
BMB
Tag numbers 2
1
Transit 0
Fig. 2.2.3.3.4(a) Triangulation cable survey method.
2.2.4 Ocean Cable Condition.
Along with the cable track, the ocean cable condition is recorded, paying particular attention
to areas of potential failure. In general, the location of any condition is given as best as
possible in relation to the numbered tags or float; e.g. "20 feet seaward of tag 10" or " 10
meters shoreward of float 8". The exact location of particular conditions should be surveyed as
described in section 2.2.3.3.4. Table 2.2.4(a) lists all conditions which should be watched for
and recorded, and specifies those conditions which must have their location surveyed. Table
2.2.4(b) lists the measurements which are required at certain conditions.
Page 8
Table 2.2.4(a).
Matrix of Observations Cable Inspection Survey - Observation of Condition of Ocean Cable System.
____________________________________________________________________________________________________________________________________________________________
Abrasion Cathodic Junctions,
Cable protection Immobilization protection Environment terminations
system system system of cables
____________________________________________________________________________________________________________________________________________________________
1. Extensive damage 1. Deterioration of abrasion 1. Missing or 1. Missing or damaged 1. Evidence of major 1. Termination
to outer coating protection (corrosion or bent fasteners anodes wave action. cable stopper
abrasion)
2. Deterioration 2. Loose nuts 2. Long spans 2. Overall reduction 2. Presence of natural 2. Condition of
of armor wires and bolts without fasteners of size or man-made debris termination
3. *Broken armor 3. Missing nuts 3. Deterioration of clump 3. Pitting of anode 3. Evidence of seismic 3. Damage to wire or
wires and bolts anchors or fasteners action outer armor
termination or junction
4. *Broken cable 4. Evidence of non-wave 4. Movement of anchor 4. Amount of marine 4. Evidence of local 4. Sharp bends
induced loads growth fishing or kinks
5. *Sharp bends 5. *Missing or separated 5. Movement of cable 5. Poor contact of anodes 5. Abrupt change in
sections between fasteners amount of marine
growth in area of cable
6. *Suspensions 6. Amount of marine 6. Loose fasteners 6. Condition of jumpers" 6. Erosion or accretion of

growth sediment along cable
7. *Kinking or 7. *The end of the split 7. Uncovering 7. Inorganic fouling of 7. Presence of ice scour
birdcaged armor pipe protection of trenches anode tracks
8. *Protruding cable 8. Missing concrete or rock

core overburden on trenches
9. *Buried cable 9. Damaged or missing rock

bolts or U-rods
10. Amount of marine

growth
11. Evidence of non-wave

induced loads
12. Large deviation from

expected track of cable
____________________________________________________________________________________________________________________________________________________________
* Exact position should be surveyed in.
Page 9
Table 2.2.4(b)
Measurements required.
Measurement Photograph
Discrepancy Tolerance Illustrations
to be taken required
Broken
armor 0 Number of
N/A Yes
wires wires
Abrasion of: Circ.

Length
(a) Cable 5% Circumference (a)
Yes
(b) Split 5% Length (b)
pipe
Length
(c) Rock 5% Width, length (c) N/A
Corrosion N/A N/A N/A Yes
Diameter,
Bends/ 5% or angle Diameter Angle Yes
kinks
subtended
Missing/ Number of
Yes as
loose split 0 sections N/A appropriate
pipe loose
Missing/ 5% Number of Yes as

N/A
loose nuts bolts appropriate
Circ. Length
Birdcaged Circumference,
armor 5% Yes
length
Length of span Length of span
Height
Suspension 5% Height
Height Yes
off bottom
Height off
bottom
Page 10
2.2.5 Sensor Unit Condition.
The condition of sensor units is to be recorded, when applicable, paying particular attention to
areas of potential failure, either in the sensor and related components, or in the supporting
frame. The inspection OIC should be made familiar with the sensor units by the customer in
order that an effective inspection can be carried out. A suitable table or diagram, similar in
concept to the tables for cable condition, should be drawn up.
In general, the sensor unit inspection results should include supporting frame orientation and
location, condition of the frame, armor termination on the ocean cable, electronic housing(s),
connecting cables and electrical connectors, and the sensor(s).
2.3 Inspection by ROV's.
The inspection of ocean cables in water depths beyond those able to be reached by divers can
be done using ROV's. Manned submersibles can also be used though they are not as cost
effective as ROV's and generally require a dedicated support vessel. The ROV should be able to
operate down to at least 1/2 n. mile - 1000 meters depth, the maximum depth for plowing ( at
present, though it is likely to increase to 1 n. mile - 2000 meters ) . If the ocean cable is not
buried then a simple ROV with a good television camera and effective lighting will be adequate.
If the ocean cable was buried during laying or has become buried, then a cable repair ROV will
be required to allow tracking of the buried ocean cable ( see Section B.4 ). To allow a reasonable
accuracy in determining the ROV's position, some form of short baseline underwater acoustic
navigation system should be used in conjunction with the navigation system on the support
vessel.
The inspection is relatively straightforward. The support vessel takes position over one end of
the section of the ocean cable to be inspected, the ROV is lowered into the water and then
descends to the bottom. After locating the ocean cable, the ROV swims along the cable looking
for damage if the cable is not buried, or looking for deep scrapes into the bottom that may have
damaged the cable, if buried. For buried cable, it may be necessary to unbury the cable at deep
scrapes to check its condition, and then rebury it. If damage is found its location, and the type
of damage ( see Table 2.2.4(b) ) are recorded and pictures taken ( still or video ). At the end of
the inspection the ROV surfaces and is recovered by the support vessel. The information on
possible damage is sent to the section responsible for the maintenance of the system for
assessment.
2.4 Inspection by Side Scan Sonar.
Side scan sonar is a relatively cheap and quick way of inspecting the bottom along a cable
route. It cannot examine the ocean cable in fine detail, but if done on a regular basis will show
changes to the bottom and evidence of activities such as bottom trawling that may cause damage
to the ocean cable. High definition side scan sonar will in many cases show unburied section of
the ocean cable so that any substantial movement across the bottom may be detected.
The side scan sonar results are sent to the section responsible for the maintenance of the
system where they can be used to determine the need for closer inspection by divers or ROV if
it appears that changes to the bottom may have caused damage to the ocean cable.
Additional information on side scan sonar is given in General Notes, Volume 2, Section 3.4.
Page 11
3. Repair
This chapter describes standard methods used for the repair of ocean cable systems.
.
3.1 Fault Location.
3.1.1 Overview.
When an ocean cable system suffers a failure in the underwater components, the first task is to
determine the location of the fault, and its type, in order that the repair operation can be
efficiently carried out. The fault location starts at the shore stations where test equipment is
used to find the position along the ocean cable of the fault and its type. Once this has been
completed, the cable repair vessel ( normally a cable ship unless the fault is in very shallow
water or the system is very short ) is then directed to proceed to the area of the fault. The cable
ship uses its own equipment in conjunction with the shore stations, to further localize the
fault, if possible, while the ocean cable is still on the bottom, and when the cable end, or cable
ends, are onboard.
3.1.2 Fault Location from Shore Stations.
3.1.2.1 Repeatered Coaxial Ocean Cable Systems.
While coaxial ocean cable systems are no longer used for communications systems, there are
still a number in service, and other systems, such as ranges, use this technology.
Typical indication of a fault on a repeatered coaxial ocean cable system can be the power
feeding equipment tripping out or shifting its supply voltage towards the maximum or
minimum values set for the system, or the loss of signal transmission. It should be noted that
power feeding equipment can be affected by magnetic storms which can produce large potential
variations between the ocean grounds at the shore stations, which can cause similar effects to a
fault.
When an ocean cable system develops a fault, a variety of transmission tests can be conducted
by the shore stations, PROVIDED IT CAN BE ESTABLISHED that:
a) It is safe to leave the power on when the power feeding equipment has not tripped out
due to the fault condition
or
b) It is safe to re-power the system when the power feeding equipment has tripped out
due to the fault condition.
When the fault occurs close to a shore station on a very long system, it would not normally be
possible to power from the distant shore station as the system voltages would be in excess of
the safe working voltages of the high voltage capacitors in the repeaters close to that shore
station ( Power feeding equipment is designed not to exceed safe voltages in any case to prevent
possible damage ). However in most cases it may be possible to power the system from the close
shore station to conduct tests using the repeaters with the fault as a ground, for short periods.
Page 12
These tests include the monitoring of the supervisory tones generated in the repeaters which
can be used to determine the position of the fault to a given repeater or ocean cable section.
For common-amplifier repeaters, intermodulation testing may also be able to be used to locate
the fault.
When there is any uncertainty as to the safety of the ocean cable systems, the best method is to
remove the power and carry out D.C. testing to:
a) First establish whether the condition of the fault or break is such that the power
feeding equipment can be reapplied.
b) To obtain an approximate localization of the fault position.
c) Finally, to establish whether the fault or break is too far away for the power feeding
equipment to be reapplied. If this is the case then when the system has cooled downs
the terminal station, or stations, should continue with D.C. testing to obtain a good
localization.
The standard D.C. testing is based on measurements of resistance or capacitance by a

Wheatstone or similar bridge circuits ( e.g. Murray and Varley Loop tests ). For laid ocean
cables the testing becomes a process of trial and error in which interference, the effects of
repeaters and the impedance at the fault lead to ambiguous results.
An improved version of these methods uses a digital voltmeter to determine the potential
difference across the bridge with selected fixed resistances used instead of obtaining a null
using a variable resistance in one arm. The value of the unknown can then be calculated. This
improvement reduces operator effects, improves resolution particularly for insulation faults
and allows higher test voltages.
If sufficient data is available on the effect of repeaters on the propagation velocity in the ocean
cables, an impedance bridge may also be used.
If the fault is near the shore station, the use of pulse echo fault location gear can provide an
accurate location of the fault. Normally this gear is limited to checking the ocean cable out to
the first repeater only.
3.1.2.2 Repeatered Optical Ocean Cable Systems.
The indication of, location of and types of faults for repeatered optical ocean cable systems is
generally the same as for coaxial ocean cable systems, except that the signal transmission path
is separate from the power path in the ocean cable.
The same precautions as for powering the faulty coaxial ocean cable systems apply in regard to
powering the faulty optical cable system.
As with coaxial ocean cable systems, when the fault occurs close to a shore station on a very
long system, it would not normally be possible to power from the distant shore station as the
system voltages would be in excess of the safe working voltages of the high voltage capacitors in
the repeaters close to that shore station ( Power feeding equipment is designed not to exceed
safe voltages in any case to prevent possible damage ). However in most cases it may be possible
to power the system from the close shore station to conduct tests using the repeaters with the
fault as a ground, for short periods.
Page 13
These tests include the use of extended optical time domain reflectometry ( EOTDR ) to
determine the position of a fiber break. ( A power path failure without signal path failure is
very unlikely due to the design of the ocean cables and repeaters. )
The repeaters have a loop back module, or EOTDR coupling between the fiber pair forming a
circuit, so that a special modulated signal sent down one fiber will be returned by each
repeater up the other fiber, with the number of returned signals indicating the number of
repeaters before the failure. That is if the signal is loopbacked from the 1st repeater in time T
, then for the second repeater it return in time T + " T , for the third repeater in time T + 2" T ,
and so on., with " T =2 d n c where d= distance between repeaters, n= index of refraction
and c= speed of light. Figure 3.1.2.2(a) shows a simplified loop back system.
Repeater
Loop back module/
spacing
EOTDR coupling
d
Fig. 3.1.2.2(a) Diagram of loop back system in repeaters.
3.1.2.3 Repeatered Multiconductor Ocean Cable Systems.
Faults on repeatered multiconductor ocean cable systems are basically similar to repeatered
coaxial ocean cable systems, except that there is normally no sea return for signal and power.
Power can be carried by the pair forming the signal circuit, or by separate power conductors. If
the pair, or power conductors, are open to the sea, essentially there will be a short at this point
to ground.
3.1.2.4 Unrepeatered Ocean Cable Systems.
Fault localization in unrepeatered ocean cable systems is generally straightforward for

coaxial, multiconductor and optical systems. There are no powering considerations and the
length of the ocean cable is typically quite short. Testing methods include D.C. impedance and
pulse echo for electrical cables, and optical time domain reflectometry for optical.
3.1.3 Fault Location from the Cable Ship.
3.1.3.1 Underway.
The standard method used to locate a fault in the ocean cable as it lies on the sea floor is the
trailed electrode method. The shore station equipment consists of an A.C. generator able to
supply a low frequency signal ( 20 to 40 Hz, normally 25 Hz being used ) to the ocean cable,
and the related control equipment. Aboard the cable ship there is a twin conductor cable with
two copper electrodes that is towed behind the ship, as shown in figure 3.1.3.1(a), an amplifier,
Page 14
recorder and display.
To use this method the cable ship sails a course to intersect the cable route some distance on
the shore side of the fault. Once the signal from the ocean cable has been detected the cable
ship alters course and sails a zigzag course along the cable route towards the fault. The
incoming signal will grow stronger as the fault is approached and then will stop suddenly as
the fault is passed.
The picked up signal also varies from maximum to minimum according to whether the
electrodes are parallel or at right angles to the cable route. In shallow water the electrodes will
pick up the signal without being near the bottom hence towing can be at a higher speed. As the
water depth increases the towing speed must be decreased so the electrodes will be closer to
the bottom. This method is well suited to both unburied and buried ocean cables.
For short systems, both ends of the ocean cable can be energized, however this will require
some form of modulation of the signal at each shore station to allow identification of the picked
up signal.
~ 160-50m
Electrode pair
Ocean cable
Fig. 3.1.3.1(a) Trailed electrode ocean cable and fault location method.
To further refine the location of the fault an induction coil, or electromagnetic probe, can be
towed at very low speeds, as shown in figure 3.1.3.1(b), so that it hangs nearly vertically,
indicating a null when above the ocean cable.
For longer systems this method is restricted to the sections of ocean cable near the shore
stations, and is dependent on the attenuation in the ocean cable. Section A gives the method for
calculating attenuation in an ocean cable. The maximum distance from a shore station even with
low attenuation is about 350 n. miles.
An alternative method of using the trailed electrodes is to energize the electrodes with the low
frequency signal which will induce a current in the ocean cable. This is detected by the shore
station and information on the received signal is radioed back to the cable ship which zigzags
along the cable route until the fault is reached. This is known as the reversed trailed electrode
Page 15
method.
Towbody with vertical

magnetic induction coil
Ocean cable
Fig. 3.1.3.1(b) Towed induction coil ocean cable and fault location method.
3.1.3.2 Cable Ends Onboard.
When a cable end is onboard the cable ship and has been cleaned up to allow test leads to be
attached, the first test done is to determine whether this end is the good end or the end with
the fault. This is done using the cable ship's power feeding equipment and test sets. If the
transmission tests are successful the end is capped and buoyed and the other end is recovered
( if a bight was not able to be lifted ).
If the testing was not successful, the cable end is the fault end. The normal method to gain fine
localization of the fault is to use pulse echo, or optical time domain reflectometry fault
location gear, if the fault is in the ocean cable. If in a repeater ( or equalizer ) this must be
recovered, cut out and tested to check the type of fault. Transmission tests are then conducted
to check the remainder of the system between the cable ship and the shore station once the
fault has been removed to ensure that no other faults exist, and this is repeated just before the
final splice is made.
3.2 Repair Operations.
3.2.1 Overview.
The function of the repair operation is to rectify faults that have occurred in the underwater
components of the system or to replace worn underwater components that have been found
during an inspection. The repair procedures for both of these are the same except the latter is
not done in conjunction with the fault location operations.
The repair operation consists of the recovery of the ocean cable, or an array, from the sea floor,
replacing the faulty or worn components and relaying the cable, or array. When a fault has
Page 16
occurred, the repair operations are combined with sections of the fault location operations.
The description of the repair operations is broken into grappling methods, the use of cable
repair ROV's for buried ocean cable, and the repair of arrays such as used in ranges.
3.2.2 Repair Methods.
3.2.2.1 General Comments.
For shore end cables in depths of less than 0.1 n. miles - 200 meters, the normal method of
repair for a fault in the ocean cable is to replace the damaged section of the ocean cable and use
the terminal equipment to compensate for the changes due to the added length of ocean cable in
the repair. If the ocean cable is not buried then it is grappled for, either to raise a bight if the
cable is not broken, or for the two ends if broken.
If the ocean cable is buried then a cable repair ROV is the preferred method of recovery though
grappling with detrenching grapnels can be done if the ROV is not available. However
detrenching grapnels often put severe strain on the ocean cable as it is pulled from the bottom
and there is difficulty in reburying the ocean cable after the repair is complete. The cable
repair ROV can normally rebury the ocean cable after the repair. The use of cable repair ROV's
is not generally cost effective for ocean cables that are not buried, nor warranted.
If a repeater is faulty or damaged, it is recovered by grappling for the ocean cable adjacent to it
( or by using a cable repair ROV ), brought onboard, cut out and replaced. This will still
require an additional length of ocean cable to be inserted in the repair.
In deeper water, for systems where the repeater spacing is reasonably large ( 15 n. miles or
greater ) and where the cable is laid with around 6% excess slack, the normal procedure is to
lift a cable bight to the surface. However for systems where the repeater spacing is small or the
cable is laid with low excess slack ( typically 2% ) the normal technique is to cut the ocean
cable first and recover the ends separately. If the cable is broken, then a drive will have to be
made for each end.
If the repair is done by replacing the damaged cable by a new cable, the additional length of
ocean cable in the repair, typically twice the water depth, can be sufficient to substantially
effect the operation of a repeatered system with compensation at the terminal equipment or
equalizers not able to correct these effects.
For smaller coaxial ocean cables one technique that has been used is to put a section of a
larger, lower loss coaxial ocean cable where the fault is repaired to bring the total attenuation
of the longer cable length between the repeaters back to the standard values. For example, with
the BPO 0.99 inch coaxial ocean cable it is possible to replace 8 n. miles with 12 n. miles of a
1.5 inch coaxial ocean cable which gives approximately the same attenuation, which allows
repairs to be done in up to 2 n. miles - 4000 meters depth with this technique.
An alternative technique is to use a repair repeater. This has the advantage of not being
limited to smaller coaxial ocean cables and can be used with any ocean cable type. The repair
repeater characteristics are such to cancel out the additional loss in the length of additional
ocean cable used in the repair This additional length would normally be set as that needed for
repair at the deepest point in the system that repair was considered feasible. In repeatered
optical ocean cable systems this is the only repair method used.
It should be noted that if a repeater is recovered during the repair it is normally replaced even
if it is not faulty as it is possible the repair operation may have caused some damage that will
Page 17
show up later on.
In planning the repair operation it is necessary to ensure that the performance of the system is
not changed by the repair.
3.2.2.2 Procedure Using Grappling.
Prior to the beginning of the repair operation, calculations must be done to determine the exact
procedure for the repair. These include grappling parameters, if it possible to lift a bight to
the surface, cable tension and configuration during recovery. The methods are given in
Chapters 2 and 4, Volume 2 of the Handbook, with the data for the ocean cable system from the
Laying Data Book for the system ( see Section 7.8, Volume 6 of the Handbook ).
If it is not possible to lift a bight to the surface, due to low excess being laid or tension in the
cable being too high, then a cutting drive is made to cut the cable with a cutting grapnel ( See
Chapter 2, Volume 4 of the Handbook ). On completion of the cutting drive, the grapnel is
changed to one suitable for picking up the cable and a drive made for one end, about 2.5 times
the water depth from the cut. Alternatively a cut and hold grapnel could be used first to both
cut the cable and bring one end to the surface.
When the end has been grappled and brought inboard it is cut and tested. If this is the good
end, it is buoyed and the other end is grappled and brought inboard and made up on the cable
engine. The ocean cable is recovered until the fault is inboard of the cable engine. The cable is
cut inboard of the cable engine and the repair cable ( including a repair repeater if required )
is spliced in. The cable ship then lays the repair cable back to the buoyed end which is
recovered, and spliced into the repair cable and made ready for slipping. Tests are conducted
on the repaired system and if successful, the bight is slipped to complete the repair.
If the first end is the end with the fault, it is recovered until the fault is inboard. The cable is
cut and buoyed. The second is grappled and when inboard is made up on the cable engine and
the repair cable spliced in. The repair then proceeds as before.
When a bight can be lifted to the surface the procedure is the same as above except that both
ends are available for testing after grappling which simplifies the work required.
The procedures for the grappling are covered in Chapter 3, Volume 4 of the Handbook, cable
buoys and the rigging of their moorings in Chapter 4, Volume 4 of the Handbook. Methods for
working ocean cables during repair operations, and cable buoys are covered in Volume 5 of the
Handbook.
3.2.2.3 Procedure Using Cable Repair ROV's.
Once the fault has been generally localized, the cable repair ROV is deployed and proceeds to
the bottom where it searches for the ocean cable. Once found, the ROV proceeds along the cable
to localize the fault with its own sensors. The ROV then uncovers the cable and cuts it. It then
places grippers on the cable, each side of the cut. If the point of failure is obvious, the
grippers are placed each side of the fault. A line lowered from the cable ship is now clipped to
one of the grippers. If necessary, the ROV uncovers more cable to make raising the ends to the
surface easier, particularly if it is deeply buried. A second line may be attached to the second
gripper, and buoyed for later recovery of this end. The ROV is normally recovered at this point.
The repair now follows the same method as for grappling until the bight is ready to be slipped.
If necessary the ROV is used to recover the second end, if it was not buoyed. Often, a line is
used to lower the bight to the bottom to ensure it lays out along the bottom.
Page 18
The cable repair ROV is relaunched and proceeds to the bottom where it detaches to lowering
line and proceeds to rebury the cable, and any repair repeater.
There are several types of cable repair ROV's are in service, the most widely used are SCARAB,
CIRRUS, and MARLIN. Information on cable repair ROVs is given in Annex B.
The cable repair ROV's are also used for cable burial after laying and for inspection of ocean
cable.
3.2.2.4 Procedure for Arrays.
3.2.2.4.1 Nearshore Arrays.
The following is an outline of the typical methods used to repair arrays situated in the
nearshore area. It should be noted that the actual method depends on the type of array and the
way the sensor units are cabled, and the type of fault. Repairs are normally conducted using a
lighter or similar vessel and divers. If grappling is required this can be done using the lighter
or a tug ( See Section 3.2, Volume 4 of the Handbook ).
Repair of a faulty sensor unit can be done using a lighter, which is moored over the unit with a
multi-leg type mooring to allow accurate positioning and control movement. To lift the sensor
unit when it is being worked from the water onto the deck of the lighter, and back into the
water, a suitable crane or davit is required, situated in a position to plumb the sheave or
fairlead. Divers attach a lifting line to the sensor unit and to take the weight of the attached
ocean cable a second line is attached to a stopper made up a short distance along the ocean
cable from the sensor unit. Using these the sensor unit is brought to the surface where the
crane/davit is used to bring the sensor unit onto the deck where it is disconnected from the
ocean cable. If a replacement unit is available, this can connected to the ocean cable, functional
tests carried out and the sensor unit with the ocean cable then lowered back onto the bottom. If
the sensor unit must be taken away to be repaired, the ocean cable should be sealed and
lowered back onto the bottom. When the sensor unit is repaired, the end of the ocean cable is
recovered, connected to the sensor unit after being tested, functional tests of the cabled sensor
unit carried out and then the sensor unit and the ocean cable are lowered back onto the bottom.
As the position of the sensor unit is normally important in near shore arrays, after the sensor
unit is lowered back onto the bottom, either its position must be determined accurately, or it
may require lifting and being moved back to its correct position.
If the fault is in the ocean cable near the sensor unit, it will be necessary to first lift the
sensor unit onto the lighter and work along the ocean cable until the fault is inboard. After the
fault is repaired, normally by splicing in a new section of ocean cable, the process is reversed
to put the sensor unit back onto the bottom, noting the comment above on sensor unit position.
If the ocean cable is buried, it may be necessary for the divers to remove the covering material
to allow it to be pulled to the surface.
If the fault is in the ocean cable and far enough away from the sensor unit(s) so that lifting a
bight to the surface will not disturb them, divers can attach a lifting line to the ocean cable
using a stopper, near or at the fault. Alternatively, the ocean cable can be grappled for, though
care must be taken as this is likely to move the sensor unit(s) unless reasonable slack was laid.
The bight of cable is then lifted to the surface and the lighter is worked along the ocean cable
until the fault is on deck. A new section of ocean cable is spliced in to remove the fault and the
cable tested before the bight is lowered back onto the bottom.
Page 19
In the case where there is insufficient slack to allow raising a bight to the surface, such as
when the cable is buried or it is not possible to work the lighter along the cable due to the
tension being too high in the bight, the ocean cable must be cut first and each end raised
separately to the surface with a lifting line. The new section of ocean cable is spliced into the
good end and the lighter works its way down the other end until the fault is on deck. The fault
is cut out, the new section of ocean cable is spliced into the second end, the cable is tested and
then the bight is lowered onto the bottom, to be reburied if necessary.
Navigation used during the repair operation should be the same as was used during the
installation, particularly for determining the position of sensor units.
3.2.2.4.2 Offshore Arrays.
The following is an outline of the typical methods used to repair arrays situated in offshore
areas. It should be noted that the actual method depends on the type of array, its sensor units,
the way the sensor units are cabled, the method used to lay it and the location and type of
fault. The repair may be able to be done by a single vessel, or may require several vessels. If
grappling is required, then it should only be done by a cable ship in offshore waters. Forces in
grappling can be high and ad-hoc arrangements do not provide the safety inherent in a cable
ship, or the ability to readily work ocean cables during the repair operations ( See Chapter 3,
Volume 4 of the Handbook ).
If the fault occurs in the ocean cable between the sensor unit(s) and the shore stations unless
it is close to the sensor unit(s), repair operations can be carried out in the same manner as for
communication systems.
If the fault is in other ocean cable close to the sensor unit, or in the sensor unit itself, then
recovery of the sensor unit(s) must be undertaken, The method used depends on two factors:
whether the sensor unit was laid with the ocean cable or a lowering line was used; and if the
strength members are broken in the ocean cable.
If the sensor unit was laid with the ocean cable and its strength members are intact, then the
repair is done by first grappling for the ocean cable inshore of the sensor unit, cutting the
ocean cable and buoying the inshore end, and then recovering the sensor unit(s) with the
offshore section of the ocean cable in the reverse manner to the laying. On completion of the
repair, the sensor unit(s) is relayed using a new section of ocean cable, and this new ocean
cable is then spliced into the buoyed inshore end, functional tests carried out and the bight
slipped to complete the repair operation.
If the sensor was laid with a lowering line that was left on the bottom, this line can be grappled
for and used to recover the sensor unit. After completion of the repairs and functional testing,
a new line should be used in the relaying of the sensor unit as the original line is likely to
have been damaged by the grappling.
For sensor units laid with a lowering line that was released and recovered, it will be necessary
to attach a lifting line to the lifting point on the sensor unit. This is best done by a ROV. If the
specialized cable working ROV's are available they can be used, however their complexity is
not required and a simpler ROV, such as the CURV type, can be used. Alternatively,if a manned
submersible is available, it can be used. The attachment of the lifting line follows the same
method as for attaching a line to an ocean cable, except the end of the line has a special clip
suited for the lifting point on the sensor unit and to fit the manipulator of the ROV. After the
sensor unit has been recovered, repaired and functional tests done, it is relaid using a line
fitted with a release at is bottom end, in the same manner as used during installation.
Page 20
When the ocean cable is broken close to the sensor unit it is necessary to recover the sensor
unit with a lifting lines even if laid using the ocean cable, and then grapple for the inshore end
of the broken ocean cable. When the end is recovered, it is buoyed. If the sensor unit was laid
using the ocean cables then a new length of ocean cable is made up onto the sensor units
functional tests done, and the sensor unit is relayed. This new section of ocean cable is spliced
into the buoyed end of the inshore section of ocean cables functional tests done again, and the
bight slipped. When the sensor was laid with a lowering lines a new section of ocean cable is
made up onto the sensor unit, spliced into the buoyed ends functional tests done, and then the
sensor unit is relayed with the lowering line in the same manner as used in the installation.
Navigation systems, for both surface and underwater positioning. should be the same as used in
the installation to ensure that the position of sensor unit(s) is relative to the same frame of
reference.
Page 21
4. Jointing and Splicing of Ocean Cables.
This chapter contains general methods for the jointing and splicing of the conductors and
armor wires in ocean cables.
4.1 Introduction.
The jointing of conductors and the splicing of armor wires is regularly done with ocean cables,
both in the cable factory and at sea during installation and repair.
This chapter describes the general methods used mainly at sea during installation and repair.
The methods used in the cable factory for jointing conductors follow the same procedures, but
are normally done under very clean conditions and do not have the urgency required for work
onboard ship. Factory armor splices are normally done via standard terminations such as
described in Volume 7 of the Handbook.
It should be noted that the conductor jointing methods described are those generally in use,
however, for some conductors there may be very different techniques proscribed by the cable
designers or manufacturers.
4.2 Jointing Conductors.
4.2.1 Overview.
The jointing of conductors can be split into several categories, depending on conductor type
and size. The two main categories are electrical conductors and optical conductors.
Electrical conductors can be further broken down by insulation diameter, center conductor
type ( solid, stranded, or strength member ) and size, and if coaxial, the return tape type and
sheathing form. These characteristics determine the method to be used for the joint.
Optical conductors and power conductors for optical ocean cables are jointed with universal
jointing and coupling technology ( UJ/UC ).
4.2.2 Equipment.
4.2.2.1 General.
In jointing ocean cable conductors there are several major items of specialized equipment used.
The following sections give a description, usage and qualification of typical units.
4.2.2.2 Center Conductor Jointing Equipment.
4.2.2.2.1 Swaging Tool - Small Conductors.
4.2.2.2.1.1 Description.
The most efficient method of joining small conductors either of solid or stranded construction
is by a swaged sleeve or ferrule. The sleeve consists of a tube of copper with a small
indentation at its center to provide a stop for the ends of the conductors when they are pushed
in from each end, A hand swaging tool, such as made by Nicopress, is used to swage the sleeve
onto the conductors. Various sizes of sleeves, tools and interchangeable dies accommodate the
Page 22
different sizes of conductor.
4.2.2.2.1.2 Usage.
The insulation is stripped off the conductor on each of the ends to be joined and cleaned with
solvent. The sleeve is pushed onto the end of one conductor until it reaches the stop, The sleeve
is then swaged on at two points. The operation is repeated for the other conductor.
Two more swages are made on each end at right angles to the first two, as shown in figure
4.2.2.2.1.2(a), A pair of duckbill pliers should then be carefully used to remove any burrs or
sharp edges caused by the swaging of the sleeves to keep it as smooth as possible.
First set of swaging,

two each end
Indentation for
centering conductors
Conductor Sleeve
Second set of swaging,

two each end at
90 degrees to first
Fig. 4.2.2.2.1.2(a) Swaging sleeve onto conductors.
4.2.2.2.1.3 Qualification.
No qualification is generally needed with this equipment.
4.2.2.2.2 Conductor Brazing Machine.
The brazing of central conductors of ocean cables is done onboard ship by a portable brazing
machine of the type shown in figure 4.2.2.2.2.1(a). Similar machines are used in cable
factories. The unit consists of a tapped transformer, voltage selector- switch ( for tappings ), a
contactor for current switching, brazing jaws, and an upset or pressure control for the brazing
jaws. An external timer is provided for. Figure 4,2,2.2.2.1(b) shows a typical circuit diagram
for a brazing machine.
To accommodate the different sizes of conductors,, a system of split collets is used to grip the
conductors and hold them in the jaws. For larger diameter conductors, the jaws are fitted with
water cooling to allow for the larger currents used, and jaw extensions are used.
Upset
Manual Brazing control
pilot lamp jaws Auto/manual
Press button for switch
manual operation
Auto welding
pilot lamp
Press button for
Mains voltmeter auto welding
Press button for

auto brazing
Auto brazing
Mains pilot lamp
connecting lead
Voltage control Earth

switch terminal
Fig. 4.2.2.2.2.1(a) Portable brazing machine.

Page 23
Page 24
In addition, most machines can also do welding of mild steel cores in composite conductors and
cut the high tensile steel core of center strength member conductors by burning through.
Transformer
1
L Brazing jaws
10
Voltage contact Outlet socket

(10 position) switch
N
Neon
pilot
E Pushbutton Auto braze
Auto braze Neon pilot
Manual
Pushbutton Manual
Contactor Auto weld

Neon pilot
Auto/manual
3 position switch Pushbutton Auto weld
Microswitch
Fig. 4.2.2.2.2.1(b) Circuit diagram - portable brazing machine.
4.2.2.2.2.2 Usage.
The normal brazing done on central conductors is butt brazing. The ends of the two conductors
are first cut off square and the insulation stripped back to expose the conductors sufficiently
for inserting in the jaws ( and collets ) of the machine. They are then placed in the brazing jaws
using the appropriate collets with their ends touching, and carefully aligned. Using the upset
control they are moved apart and a brazing insert placed between them using tweezers to hold
the insert. The insert must be cleaned just prior to insertion as must the ends of the
conductors, with a suitable solvent. The upset is then restored to clamp the insert between the
ends, as shown in figure 4.2.2.2.2.2(a).
The correct voltage is selected and the brazing current applied until the junction reaches a
cherry red temperature and the brazing material flows. On cooling, the conductor is removed
and cleaned.
Stranded or composite center conductors must be first tinned before being joined together. This
is done by exposing sufficient conductor on each end to pass through both jaws. Each end in
turn is placed into the jaws, and collets, and a sleeve of tinning ( brazing ) material wrapped
around the middle point, as shown in figure 4.2.2.2.2.2(b). Current is then applied until the
tinning material flows into the strands. After cooling, the conductors are cut off in the-center
of the tinned area and brazed together as for a solid conductor.
Page 25
Brazing insert
Collet Collet
Center conductor
Fig. 4.2.2.2.2.2(a) Arrangement for brazing central conductor.
Brazing metal
Collet Collet
Center conductor
Fig. 4.2.2.2.2.2.(b) Arrangement for tinning one end of a stranded

or composite center conductor.
Conductors with a copper sleeve over the composite core do not normally have to be tinned and
can be brazed directly.
For welding mild steel cores, the ends are prepared as shown in figure 4.2.2.2.2.2(c) and
placed into the jaws, A ferrule is placed on one end just outside the collet. The machine is set
for welding and the current applied. On completion of the welding, the weld area is cleaned and
the ferrule slid over the joint and brazing wire wrapped around each end. The machine is set
for brazing and the current applied until the brazing wire melts and completely flows around
the ferrule. Figure 4.2.2.2.2.2(d) shows the arrangement of the ferrule just prior to brazing.
Page 26
Collets
Ferrule
Fig. 4.2.2.2.2.2(c) Arrangement for welding mild steel cores of

Wire bindings
on ferrule
Collet Collet
Brazing
wire
Fig. 4.2.2.2.2.2(d) Arrangement for brazing ferrule on mild steel

core composite center conductor.
For cutting high tensile steel cored center conductors the conductor is marked at the desired
cutting point and placed into the jaws with the mark central, as shown in figure 4.2.2.2.2.2(e).
The machine is set for brazing and the current applied until the conductor is burnt through.
During welding and cutting of center conductors, it is essential that operators wear safety
goggles or face shields.
In order to ensure that brazing and welding are correctly carried out, it is necessary that tests
be conducted on samples of the conductors to get correct voltage setting upset and times.
Page 27
Mark on
center conductor
Collet Collet
Fig. 4.2.2.2.2.2(e) Arrangement for burning through high-tensile

steel cored center conductor.
Qualification of the brazing machine is done by making six brazes for each conductor size and
six welds for each composite conductor size. The tensile strength of the jointed samples must
not be less than 90% of an unjointed sample in all cases. In the case of brazed joints, the
elongation of the jointed sample must be not less than 15%. For welded joints, the tensile
strength of the jointed samples must be not less than 85% of that of an unjointed sample.
Where tensile test facilities do not exist, as onboard ship, a torque test may be substituted for
all conductors less than 1/4 inch - 6 mm diameter. One end is firmly gripped in a vise, and the
other end in a carpenter's brace with the joint in the center. Twisting is carried out until the
conductor breaks. Joints which pass this test are those which break at a point outside the
braze.
4.2.2.2.3 Swaging Press for Center Strength Member Ocean Cables.
Swaging presses for center strength member jointing are small, specialized hydraulic presses
with either hand or electric operation. There are several sizes to suit different ocean cables
and each size has sets of dies to suit the cables in its range. A typical hand operated unit of
100 ton capacity in shown in figure 4.2.2.2.3.1(a). Units of up to 200 ton capacity are available
if required.
The press consists of a hydraulic pump with controls and the compression unit, mounted on a
wheeled trolley for shipboard use. The compression unit is specially designed to take
interchangeable sets of dies and to allow the upper portion to be removed so that a jointed cable
can be removed.
Page 28
Fig. 4.2.2.2.3.1(a) Swaging press for jointing center strength member.
4.2.2.2.3.2 Usage.
The press is set up for a given cable by retracting the ram in the compression unit, the upper
portion is removed and the required set of dies installed.
The two ends of the cables to be joined are prepared by first cutting off the ends squarely with
a circular saw. The various parts of the cable are cut back from each end to expose the central
conductor and strength member. These are then prepared to suit the ferrule being used, and
cleaned thoroughly in solvent.
The prepared ends are now inserted into the ferrule which in turn, is placed into the lower die
in the press. The upper die and the removable section is replaced and locked home. The
position of the ferrule in the dies is checked and adjusted if required. The dies are closed
gently on the ferrule and its position rechecked. When satisfactory, the full pressure is
applied to completely close the dies and perform the swaging.
Depending on the ferrule design and the press, a single operation may complete the swaging.
However, this may not be so and the complete swaging may require several movements of the
ram with the ferrule being repositioned between each to swage along the full length of the
Page 29
ferrule.
On completion of the swaging, the ram is retracted and the upper portion of the compression
unit and its die are released and removed to allow the cable to be taken out. The ferrule must
now be checked to ensure that the swaging is successful and that the conductors have been
captured under the ends of the ferrule.
Figure 4.2.2.2.3.2(a) shows the stages in a typical swaging process on a central strength
member of a coaxial cable. In this case, as the ferrule in swaged its outward movement aids in
ensuring the electrical continuity of the central conductor.
Strength
Conductor member
Cable ends stripped back and cleaned
Ferrule
Cable ends inserted into ferrule
Conductor captured
under ends of ferrule
Ferrule swaged onto center strength member
Fig. 4.2.2.2.3.2(a) Steps in swaging ferrule on center strength

member ( coaxial cable ).
For each set of dies, six consecutive swages are made on sections of the central strength
member. These test swages must conform to the cable manufacturer's specifications for this
type of joint. If any section of the press is replaced, then the machine must be requalified.
Page 30
4.2.2.3 Injection Molding Machines.
4.2.2.3.1 Description.
Injection molding machines are used for remaking the polyethylene ( or polypropylene )
dielectric over conductors and sheaths on coaxial cables.
The unit used in cable factories for this work are normally fixed, have granular feed for the
polyethylene, and do one type of molding per machine. The range of molding work that can be
done in a factory is essentially unlimited. These units also normally have substantial
instrumentation for checking work.
For shipboard use, molding machines are portable, and use a slug feed for the polyethylene.
The range of molding is restricted to that needed for installation and repair. There are several
different types of machine in use, they may have one mold or interchangeable molds, and
polyethylene feed may be by spring or pneumatic drive. The three principal types are shown in
figures 4.2.2.3.1(a), 4.2.2.3.1(b) and 4.2.2.3.1(c). Most spring feed units cannot be recharged
during a molding operation, though the SCANT No 3 unit has this ability. The pneumatic driven
machines are normally designed for recharging, allowing a single slug size to be used for all
types of molds. For the description of jointing in this handbook machines of this type are used.
Power
Mold plug
Spring
heaters
injector
Replaceable
molds
Hinge
Upper section
of unit
Clamping
screw
Injection
port
Power Water
plug cooling
Spring
injector
Lower section
of unit
Fig. 4.2.2.3.1(a) Injection molding machine, spring feed type,

single load, shown without cable clamps.
( STC type )
Page 31
Pressure Ram Barrel Barrel extension

springs carriage
Operating assembly with heater
handle
Rod calibrated to Mold thermometer Nozzle
show displacement s towed position thermometer
and pressure
Nozzle with
cover cap
Simmerstats Pilot Switches Fuses

lamps Outlet
sockets
Fig. 4.2.2.3.1(b) Injection molding machine, spring feed type,

shown without interchangeable molds and
cable clamps ( SCANTI No.2 type ).
Page 32
Compressed air,
water and drain
Air driven
piston assembly
Ram
Barrel opens to
Automatic
take polyethylene
temperature
slugs
control unit
(in base) Band heater
and nozzle
Upper section
of mold
Fixed cable
clamp
Detensioning
lever Lower section
Spring of mold
tensioned
Mold
cable clamp
clamp
Fig. 4.2.2.3.1(c) Pneumatic driven feed molding machine with automatic

temperature control, single mold and clamps (WECo type ).
Page 33
Figure 4.2.2.3.1(d) shows the basic components common to all machines and a pneumatic drive
for the ram. Instrumentation is normally limited to a dial thermometer in the mold and
sometimes on in the nozzle. The control of the temperature at the nozzle and the mold can be by
rheostats ( using the thermometers ) or by a simple automatic control. The heater for the nozzle
is normally of the band type while the molds use cartridge type heaters. The water cooling is
required to ensure that the dielectric or sheath adjacent to the mold area does not become soft
and be extruded under the molding pressure, and, after the injection process is complete, the
water cooling aids in cooling the mold. Some systems also include an air blast over the mold to
further aid cooling. The clamp at each end of the mold apply tension to keep the conductor
central in the mold as the polyethylene is injected in.
Ram drive
air inlet
Air Piston
cylinder
Ram retract
air inlet Ram
Charging
Cover chamber
Band heater
Nozzle Upper section

of mold
Jaws spring Jaws fixed

tensioned Water cable clamp
cable clamp cooling
passages Lower section
Air Molding Cartridge of mold
cooling cavity heaters
holes
Fig. 4.2.2.3.1(d) Basic components of air driven injection

molding machine.
Page 34
For small conductors, such as quads, the molds are normally designed to take four conductors
simultaneously. If less than four conductors are to be done, the spare molds are filled with
short length of scrap conductor.
For larger conductors, the molds take only one conductor at a time, and with increasing
diameter of the dielectric, the length of the molds generally increases.
Injection of the polyethylene into the mold can be from a single point, or from two points
opposite one another. This latter method has the advantage of not tending to wash the conductor
off center. Figures 4.2.2.3.1(e) and 4.2.2.3.1(f) show the arrangement of two molds, one for a
quad and one for a coaxial cable.
Water Nozzle Water

cooling attachment cooling
Injection
Cores (4) ports (5)
Plan view - lower section of mold
Cooling Upper section Cartridge

holes of mold heaters
Lower section
of mold
Front view - mold closed, clamps and

wiring not shown
Fig. 4.2.2.3.1(e) Injection machine mold for quad cable

( WECo type ).
Page 35
A Front section B Rear section

C Bore D Mold clamps
E Flexible leads F Plugs
G Mold heaters H Water cooling pipes
J Cooling fins K Injection port
Mold open
Mold closed
Fig. 4.2.2.3.1(f) Injection machine mold for dielectric of

coaxial cable ( SCANTI ).
Page 36
Cable ships normally provide points along the cable working deck with fresh water, power,
compressed air and drains for molding machines. Use on auxiliary vessels without these
facilities requires a portable generator for power, compressed air from a portable compressor
or air bottles, with cooling water being provided by a recirculating system using an electric
pump and a bucket. Recommended practice is that molding machines use 115 VAC electric
power for improved safety.
4.2.2.3.2 Usage.
The operating method for injection molding machines will vary from machine to machine, but
the following is typical of a pneumatic driven feed machine with automatic temperature
control. It is assumed that a qualification run has been done and the machine is ready for use
with the nozzle beater and cooling water on.
The mold and the cable clamps are opened. The moveable cable clamp is brought to its
untensioned position. The cable(s) with its conductor(s) joined is placed in the mold with the
section with the cut out dielectric central. The cable clamps are closed and tightened on the
cable(s). The tension is applied. If the tension pulls the cut away dielectric significantly off
center, it will be necessary to adjust the cable(s) position to make it central under tension. The
mold is then closed and clamped tight.
The dial thermometer is inserted into the mold and mold heating applied. After the mold has
reached the required temperature and stabilized, a polyethylene slug is placed into the barrel
and the air pressure applied to the ram to inject the polyethylene into the mold. For a large
mold, it may be necessary to repeat this operation several times, until the ram does not reach
the fully extended position. After a short period at molding pressure and temperature, the
mold heaters are turned off and cooling begun. It is essential that pressure on the ram be
maintained to ensure that any initial contraction of the polyethylene in the mold is
compensated for.
After the temperature in the mold drops below the removal temperature, the ram is retracted
and the mold and cable clamps opened and the cable(s) removed.
The required temperatures for molding may vary slightly with molds and polyethylene type,
but typically are about 400o F to 425o F ( 185o C to 218o C ) for the mold at injection of the
polyethylene and about 120o F ( 50o C for cable removal ).
4.2.2.3.3 Qualification.
Both the injection molding machine and it operator must undergo regular qualification tests.
This is done using short lengths of cable. The resulting moldings must meet visual, and for
larger cables, X-ray examination and pass flexing tests.
Visual inspection under strong light behind the polyethylene, must show no boundaries
between the injected and parent material, no bubbles or inclusions, and if able to be seen, the
conductor must be central, X-ray inspection must similarly show no boundaries bubbles or
inclusions and the conductor must be central. The examination of the X-ray film should be
done using magnifiers and good back lighting. To ensure effectiveness of the X-rays, test
samples should be included alongside the molded portion of the cable.
Flexing tests normally for the core of a cable consist of cutting the core into halves lengthwise
for 0.620 inch - 16 mm diameter cables and smaller, or into quarters for larger cables, and
flexing the sections, minus the conductor over a stated radius at the point where the joint
Page 37
material amalgamates with the original insulation, This joint must withstand fifty 90o flexes in
each direction at approximately 60 flexes per minute without cracking. It is then repeated for
the other end of the molding on the same specimen. The required bending radius is shown in
table 4.2.2.3.3(a).
For a sheath, a section is stripped off and flexed over a 1/2 inch - 12.7 mm radius at the point
of the amalgamation of the injected and parent materials. Normal practice is twenty five 90o
flexes in each direction at approximately 60 flexes per minute without cracking.
Table 4.2.2.3.3(a)
Core Flex Test Bending Radii.
Core Diameter Bending Radius
mm inch mm inch
____________________________________
7.9 0.310 6.3 1/4
11.7 0.460 6.3 1/4
15.8 0.620 6.3 1/4
23.8 0.935 12.7 1/2
25.2 0.990 12.7 1/2
25.4 1.000 12.7 1/2
37.4 1.47 25.4 1
38.2 1.500 25.4 1
43.2 1.700 25.4 1
____________________________________
To test a complete joint it is necessary to use a static sheath type machines however this type
of test is only suitable for use in a cable factory or shore base. The test cable containing the
joint is made up to be approximately 9 feet - 3 meters long with the joint at its middle point.
The cable is clamped at its ends to prevent any relative motion between the layers in the cable.
The cable is positioned between the two static, semicircular V-sheaves of 72 3 inches - 1830
76 mm diameter and Vee angle of 45 5 degrees, mounted adjacently in line. The cable is
clamped at the abutment of the sheaves such that during each flexing cycle the complete joint,
when displaced through 90 degrees on each side of the center position makes continuous
contact round the sheaves. There is to be no visible signs of external cracking of the sheath
molding during the application of 50 flexes.
4.2.2.4 Return Tape Jointing Equipment.
4.2.2.4.1 Brazing.
The brazing of copper return tapes on coaxial ocean cables is done with brazing tongs driven
from a transformer of the type shown in figure 4.2.2.4.1.1(a). A typical transformer used for
this form of brazing has a series of output terminals for tapping the transformer to give 2, 4, 6,
Page 38
9 and 12 volts with a maximum rating of 1500 Watts. The unit is controlled by a foot switch.
The tongs have a pair of electrodes at their end which are replaceable and come in different
types to suit the kind of brazing being done.
Fig. 4.2.2.4.1.1(a) Transformer unit for brazing return tapes.
4.2.2.4.1.2 Usage.
The electrodes on the tongs are selected for the work to be done, flat carbon electrodes for
general tape brazing and for brazing across return tapes, one electrode is a copper block with a
concave profile to accept the cable core and the other is a carbon rod held in copper jaws.
The return tapes to be joined are first cleaned and the brazing material placed between them at
the joint. The tongs are slid around the tapes and closed. Power is applied until the brazing
material flows. In order that the brazing be carried out correctly it is essential that test
samples be done first to get the correct voltage selection.
Six test tapes are brazed consecutively. They are then subjected to a tensile test where the
brazed joint must exhibit a strength of at least 80% of an unjointed sample and at least 15%
elongation.
4.2.2.4.2 Cold Pressure Welding.
Cold pressure welding is normally used for aluminum return tapes or for joining aluminum to
copper return tapes. The tool shown in figure 4.2.2.4.2.1(a), consists of a hand operated-
Page 39
hydraulic pump and a head unit. The head has a punch driven by a hydraulic ram and an anvil.
Punches and anvils are interchangeable to suit the form of return tapes.
Fig. 4.2.2.4.2.1(a) Cold pressure welding tool for return tapes.
4.2.2.4.2.2 Usage.
The punch and anvil required for the work to be done is mounted on the head, the square slot
type for work where the tool can be held square on to the tapes, the angled type for tapes set at
an angle to a longitudinal outer conductor and a special acute angled type for longitudinal
outer conductors.
The tapes to be joined are first cleaned and placed together the inserted into the slot in the
head. Pressure is applied until the punch is driven home, pressure is the released and the
joined tapes removed.
Six test tapes are welded consecutively and must pass both visual inspection of the welds and
tensile test laid down by the cable manufacturer.
4.2.2.5 Fusion Splicer for Optical Fibers.
The fusion splicer is used in jointing optical fibers for the universal joint and coupling
technology ( UJ/UC ). A typical fusion splicer of the type used is shown in figure 4.2.2.6.1(a).
The fusion splicer has three supporting pieces of equipment, a jacket stripper, an ultrasonic
Page 40
cleaner and a fiber cleaver.
The fusion splicer produces a record of each splice, including fiber image, proof load and
estimated loss in splice, and displays these results on a screen.
Fig. 4.2.2.5.1(a) Fusion splicer for UC/UJ technology

4.2.2.5.2 Usage.
When the optical fibers are available from the ends of the two cables that are being spliced
together, the matching fibers from each, in turn, are spliced together. Firstly the jacket on each
fiber is removed, the fiber ends are cleaned in the ultrasonic cleaner, each fiber is cleaved to
produce an end suitable for fusing. The both fiber ends are placed in the fusion splicer and
fused. If the splice is considered satisfactory, the next matching fibers are done, if not, the
process is repeated.
4.2.2.5 X-Ray Camera.
Special portable X-ray cameras are used for checking injection moldings of the larger cable
sizes done onboard ship. A typical unit is shown in figures 4.2.2.6.1(a), and consists of the
exposure head and the control unit which are joined by a connecting lead.
The exposure head contains the X-ray tube, H/T transformer, bias resistors, photographic plate
holder and mechanical clamps for the cable. The enclosing steel box provides protection from
the soft X-rays used. The cable clamps at each end of the box, shown in figure 4.2.2.6.1(b), are
designed to clamp the cable in position. The clamping is effected by jaws A, B and D with
adjustment for the cable size via screw C, The clamps at each end are mechanically linked
together and rotate through 150o to allow X-ray photographs from different directions.
Page 41
Exposure head
Control unit
Fig. 4.2.2.6.1(a) Portable X-ray machine.
The control unit contains the voltage control unit, meters, timer, etc., needed to drive the X-ray
tube and is powered by 115 VAC.
The X-ray film is normally supplied in envelopes which fit into a film holder, which in turn
slides into the the plate holder on the exposure head. Other support equipment required
includes test specimens, film processing equipment and viewers.
Page 42
G A
H B
C D
Fig. 4.2.2.6.1(b) Cable clamp on X-ray machine exposure head.
Figure 5.2.2.6.1(c) shows an X-ray camera of the type used for the universal joint and coupling
technology ( UJ/UC ) joint inspection.
Fig. 4.2.2.6.1(c) X-ray camera type 13 Mk. III for UC/UJ technology
Page 43
4.2.2.6.2 Usage.
After the molding is completed, the cable is placed into the exposure head with the molded
section central for a short mold or for larger molds, the section to be photographed central. The
cable is clamped into position in the jaws to prevent it moving.
The film is inserted and the covers closed. The exposure is made and the film removed for
processing. Normal practice is to rotate the cable through 90o and make a second exposure to
ensure complete coverage of the mold. For long molds, the cable is moved along and the process
repeated until all the molded length has been X-rayed. It is essential that the section(s) X -
rayed include the area at each end of the mold where the injected material amalgamates with
the parent material, to check for incomplete fusion. On completion of the X-raying, the
photographs produced should extend along the complete molded section and out into the parent
material and be from at least two directions to ensure that any defect can be found.
If possible, it is good practice to include a test piece alongside the cable section as a reference.
If the intensity of the X-ray tube cannot be adjusted sufficiently at the control unit to provide
the required low level, it will be necessary to insert a 'filter' in front of the X-ray tube to
further reduce the intensity.
After processing, the film must be examined closely under magnification to look for incomplete
fusion, voids, inclusions and washing of the conductor off center. This is best done by placing
each film negative on a light table and using magnifying graticule viewer.
4.2.2.6.3 Qualification.
Prior to use, X-ray photographs of test pieces with known flaws must be done to check the
operation and settings of the X-ray machine. If it is not possible to include a test piece in each
X-ray photograph of a cable joint, then this procedure will provide the only check of the
operation of the unit.
4.2.3 Procedures for Making Conductor Joints.
4.2.3.1 Classification.
Conductor joints can be broadly classified into three groups; small electrical conductors, large
electrical conductors and optical conductors.
The distinction between small and large electrical conductors is not clear cut. Essentially
small electrical conductors are those in which the conductor wires are normally joined by
swaged sleeves or ferrules and it is possible to examine the molded polyethylene part of the
joint by visual means only. Typical ocean cables with small electrical conductors are pairs or
quads.
Large electrical conductors are those where the thickness of the molded polyethylene is too
great for visual inspection and only one conductor is joined at a time. Typical ocean cables with
large electrical conductors are coaxial and power cables.
Ocean cables with optical conductors are of very highly specialized designs and normally the
electrical conductor surrounds the optical conductor(s) providing the water vapor barrier as
well as the power conductor. These cables are joined in a universal joint and coupling
technology ( UJ/UC ) that can be used on all types of optical ocean cables, with the insulation
being remade by injection molding.
Page 44
2.50-63.5mm Polyethylene
insulation
1.70-43.2mm
1.30-33.0mm
0.051-1.29mm
0.27-6.86mm Copper sleeve
Copper wire
0.180-4.57mm Molding
Fig. 4.2.3.2.1(a) Joint on 0.051/0.180 conductor.

Page 45
For multiconductor ocean cables with different types of conductors, it is necessary to treat the
jointing of each conductor depending on its classification.
4.2.3.2 Jointing Small Electrical Conductors.
4.2.3.2.1 Introduction.
The jointing of small electrical conductors normally occurs in multiconductor ocean cables and
sensor leads. The most common ocean cables with small electrical conductors are those with
pairs and quads.
The minimum size of conductor that can be jointed reliably is controlled primarily by the
thickness of the insulation. The smallest that is jointed is 0.041 inch - 1.04 mm diameter
copper wire with 0.130 inch - 3.3 mm diameter over the insulation, giving an insulation
thickness of 0.0445 inch - 1.13 mm. The size most commonly used for small electrical
conductors in 0.051 inch - 1.295 mm diameter copper wire with 0.180 inch - 4.57 mm diameter
over the insulation, giving an insulation thickness of 0.0615 inch - 1.56 mm. Figure
4.2.3.2.1(a) shows a joint on this size conductor.
The procedure used to joint small electrical conductors is illustrated by jointing a quad, the
most common form in use.
4.2.3.2.2. Equipment.
Type Description
Insulation Heavy duty, adjustable.

stripper
Copper sleeves To suit conductor wire size.
Sleeve swaging With dies to suit sleeves.

tool
Solvent Suitable for use with polyethylene insulation with no residue left on
evaporation.
Injection mold- Four cavity mold to suit conductor

ing machine insulation.
Light Strong directional light for visual inspection of molding.
Other equipment required includes scissors, knife, wire cutters, lint free cloth, duck bill
pliers, polyethylene slugs for molding machine, twine and fabric insulation tape.
4.2.3.2.3 Procedure.
Stage 1 Figure 4.2.3.2.3(a).
The two cable ends are on the cable working deck with the outer servings, armor wires and
armor bedding unwound and tied back leaving the cores exposed. The outer covering tape on
each core is then unwound to expose the quads.
Page 46
Armor Conductors Quad Armor bedding
First cable end Second cable end
Core binding tape
Fig. 4.2.3.2.3(a) Arrangement for cutting quads and conductors to give

staggered joint ( 4 quad cable shown ).
Page 47
As each quad is identified by its colored covering tape, it is unwound from the core, its
covering tape stripped back and the conductors cut to length. Each conductor is now identified
by the colored filler strands in the quad, and labeled using numbered adhesive tape. A typical
numbering system would be for example: a conductor identified as "23" is the third conductor
in the second quad. As most jointing is staggered to reduce the increase in the diameter of the
core over the conductor joints, great care must be taken in cutting the conductors to length, as.
shown in the figure. Exposed filler strands in the quads are cut off.
The actual length of the core required for jointing and the exposed length of each conductor
must be determined by trials done previously. Sufficient length should be allowed so that the
splicer can easily work the cable cores.
Stage 2 Figure 4.2.3.2.3(b).
The two cable ends are now tied down to the jointing table with the injection molding machine
mounted in the center. The cable ends are arranged so that the conductors, when joined, have
sufficient slack to be placed easily into the injection molding machine ( It may be necessary to
move the molding machine along the jointing table to do long staggered joints ).
Beginning at the center quad in each end ( or the inner most quad if there is no actual center
quad ), each conductor has the required length of insulation stripped off and any burrs on the
end of the wire removed. When all the conductors in the two quads to be joined are done, then
they are thoroughly cleaned with solvent and lint free cloth.
The wires in each conductor of the quads are now joined. The sleeves are first cleaned and then
swaged on, with any burrs formed being flattened using the duckbill pliers. The four
conductors are now placed into the four cavity mold of the injection molding machine and the
cable clamps lightly tightened to hold them in place. The swaged sleeves are centralized in the
molds, cable clamps tightened, rechecked, and the mold closed and the molding process carried
out.
When the mold has cooled, it in opened, cable clamps released and the four conductors
removed. The sprues are now carefully cut off. The strong light is now used to inspect each
molding. With the light behind the molding, shining into it, the position of the sleeve and wires
is first checked to see that they have remained central. Next the polyethylene insulation is
checked for proper amalgamation at each end with the parent material, for bubbles or
inclusions, etc., which may indicated an unsatisfactory mold. If all four molded joints are
satisfactory, the quad can be put aside and the next one done.
If a molding is not satisfactory, it must be redone, by cutting out the joint and redoing the
complete process. It is normally possible to arrange the conductors to compensate for the slight
shortening of the conductor that has been redone when the complete joint is consolidated.
Because the molding process takes some time, the next quad can be prepared and the sleeves
swaged on during this period, so that the overall time to do the complete joint can be reduced.
As each quad is completed, the necessary electrical tests should be carried out to ensure that
the joint is also electrically satisfactory.
Page 48
Power, air, water

supply, and drain
to injection
molding machine Injection
Jointing
molding
table Cable ends
machine
lashed to table
First Second
cable end cable end
Quads
Armor
Fig. 4.2.3.2.3(b) Arrangement of jointing table for

multi-conductor ocean cables.
Stage 3.
When all the quads are jointed, each quad is rebound, either with is covering tape or fabric
adhesive tape. Then all the quads are bundled together and carefully arranged to make them as
compact and of as round a cross section as possible. This is very important if the armor is
being spliced by an overlaid splice, and may require some fillers to be added.
The core covering tapes are now rewound around the jointed core and held in place with fabric
adhesive tape to provide a smooth round form and protect the joint.
The jointed core is now finished and can be removed from the jointing table to allow the armor
splicing to be completed.
Page 49
4.2.3.3 Jointing Large Electrical Conductors.
The jointing of large electrical conductors normally occurs in either coaxial communications
type ocean cables or undersea power cables.
The maximum size of conductor that can be jointed is essentially unlimited, but the maximum
size of conductor that has been done reliably is just over two inches for the dielectric. The
normal range of dielectric diameters jointed is from about 0.4 inches to 1.7 inches with the
center conductor ranging from about 0.128 inches to 0.478 inches diameter. On coaxial cables
with a polyethylene sheath, the sheath thickness may range from about 0.1 inches to 0.175
inches in thickness.
The procedure used to joint large electrical conductors is illustrated by the jointing of a
coaxial ocean cable. Power cables follow the same procedure up to the restoring of the
dielectric, having no return tapes or sheath.
4.2.3.3.2 Equipment.
Type Description
Conductor jointing:
Center strength member: Swaging press - with dies to suit ferrules.
Ferrules To suit center strength member/conductor.
Solid conductor: Brazing machine - with jaws and collets to suit conductor.
Dielectric restoration: Injection molding machine - with,mold to suit dielectric.
Light Strong directional light for visual inspection of molding.
X-ray machine Portable unit for cables including film, test pieces, processing
and viewing equipment.
Return tape jointing:
Brazing tongs With electrodes to suit return tape form.
Pressure welding Required if aluminum return conductor.

tool
Sheath restoration: Injection molding machine - with mold to suit sheath.
Other equipment required includes scissors, knife, wire cutters, circular saw, heavy
insulation stripping tool, copper sheath removal tool, lint free cloth, solvent, pliers, brazing
material, polyethylene slugs for injection molding machines, copper tapes or braid, copper
wire, soldering iron, solder, galvanized iron wire, twine, sleeves and spare sheath.
Page 50
Stage 1 Figure 4.2.3.3.3(a).
The two cable ends are on the cable working decks the ends have been cut off square on each
with the circular saw. If the cable is armored, the outer servings. armor wires and armor
bedding have been unwound and tied back.
The two ends are now prepared for jointing with the sheath ( if used ), return conductor,
dielectric and inner conductor ( if center strength member ) being cut away or unwound to
expose the components beneath. The exact length of each to be exposed depends on the
equipment to be used for the jointing.
Any braided or plastic sleeves to be used are now slid onto one end.
Return
tape Center Strength
Sheath Dielectric
conductor member
Center strength
member cable
Binder Teredo Return
tape tape tapes Dielectric Center
conductor
Solid center
conductor cable
Fig. 4.2.3.3.3(a) Preparation of coaxial cable end for jointing.

Page 51
Page 52
Stage 2 Figure 4.2.3.3.3(b).
A. Center strength member ( armorless ) cable.
The joining of the center strength member and the center conductor is straightforward. The
exposed conduct,ors and strength members are cleaned by first opening the strands of the
strength members and cleaning with solvent and lint free cloth. The strands are then relaid and
both ends inserted into the ferrule and the swaging carried out.
On removal from the press, the jointed center conductor and strength member are visually
inspected to ensure that the swaging has been effective and the ends of the conductors are
under the ends of the ferrule. Next electrical testing is done to check that the joint meets cable
requirements of the system.
If the testing is satisfactory, the ferrule, center conductor and dielectric are cleaned ready for
the next stage. If not, the ferrule must be cut out and the cable ends reworked and the swaging
repeated.
B. Solid center conductor or composite with no strength member.
The steps in joining the center conductor depends on its construction. If the center conductor
consists of a wire with flat tapes wound around it or some form of composite construction, it
must first be tinned. This is done using the brazing machine to tin each end in turn. When both
are tinned, they are cut off square through the the center of the tinning, making them ready for
brazing together.
For a solid conductor, both conductors are cut off square.
The center conductors are cleaned with solvent and lint free cloth, then placed in the brazing
machine jaws, aligned and brazed together. When the brazing is complete the jointed conductor
is removed and cleaned.
As an added measure for reliability, it is normal practice to solder a number of small diameter
copper wires over the brazed joint. The wires are wrapped spirally around the conductor and
soldered onto the conductor outside the brazed area. Electrical testing is now done to check
that the joint meets cable requirements of the system.
If the testing is satisfactory, the brazed conductor, and the dielectric are cleaned ready for the
next stage. If not, the brazed section must be cut out and the cable reworked and the brazing
repeated.
Center Center
conductor/ Swaged conductor/
strength ferrule strength
Dielectric Dielectric
member member
Center Brazed Copper wires

Dielectric conductor joint soldered to
Dielectric
center conductor
Fig. 4.2.3.3.3(b) Joining center conductors of coaxial ocean cables.

Page 53
Page 54
Stage 3 Figure 4.2.3.3.3(c)
The cable with its joined center conductor ( and strength member if of armorless construction )
is carefully moved to the jointing table with the injection molding machine for the dielectric
mounted on it ready for use.
The cable is laid into the mold with the cutout section of the dielectric central and the cable
clamps are then lightly tightened. Alignment is checked and the cable clamps are tightened
and tension applied. If the cutout section is moved off center, it must be readjusted to bring it
back to center. When all is satisfactory, the mold is closed and the molding process carried
out.
When the mold has cooled, it is opened, the cable clamps released and the dielectric removed-
and the sprues cut off.
Power, air, water

supply, and drain
to injection
molding machine
Injection Cable ends
Jointing molding lashed to table
table machine
First Second
cable end cable end
Fig. 4.2.3.3.3(c) Arrangement of jointing table for coaxial ocean cables.

Page 55
Stage 4.
Checking of the dielectric molding begins by using the strong light behind the molding for
visual inspection. The visual inspection is limited to the outer section of the molding and
should cover all the surface of the molding and the adjacent parent material. The inspection
must show that no bubbles, cracks, inclusions, etc., exist and that there is proper
amalgamation between the molded and parent material.
In order to check the full depth of the molding, the next step is to X-ray the molding. The
injection molding machine is moved aside and the X-ray machine exposure head mounted on the
jointing table. The cable dielectric is placed into the exposure head and clamped into position.
A series of X-ray photographs are taken, sufficient to cover the complete molding and the
parent material on either side and from at least two directions ( at 90o ) at each point X-rayed
so that all the molding is covered.
The X-ray photographs are processed and placed on a light table for inspection. Using a
magnifying viewer, each photograph ( negative ) is closely examined for faults. If a test piece is
included, then it is first examined to check that the prepared fault is visible. If not, then the
X-ray photograph must be redone at adjusted power settings.
If the molding is satisfactory, then the jointing can proceed to the next stage. If not, it will be
necessary to cut out the complete molded section and repeat the conductor joining and molding.
Stage 5 Figures 4.2.3.3.3(d) and 4.2.3.3.3(e).
A. Multiple helically applied return tapes.
Taking one tape from one end, it is relaid around the jointed dielectric. Using this tape as a
guide, a tape is selected from the other end which will match the first tape. Both these tapes
are now laid up on the dielectric so that their meeting point is at the center of the molding, and
cut to length to provide the necessary overlap. The two ends of these tapes are now brazed
together using the brazing tongs ( or if aluminum, they may be pressure welded ).
Alternatively they can be bent up at right angles to the cable and brazed or pressure welded,
then worked back down to lie flat on the cable, this making the brazing easier.
The process is now repeated for each pair of tapes until all return tapes have been joined. It is
advisable to stagger the return tape joints along the cable. Electrical testing are now done to
check continuity. If a return tape joint is faulty, it must be redone using a short section of
spare tape to make up the length due to the cutting out of the fault.
If copper teredo tape is used, they are now relayed over the jointed return tapes but are not
joined together. Similarly for a binder tape.
If the core is not jacketed, then the cable is now ready for finishing the armor splice.
Page 56
Staggered overlapping
Teredo Return Teredo
tapes spot welded
tape tapes tape
together
Alternative procedure: Tapes bent

up and spot brazed then worked
down to lie flat
Fig. 4.2.3.3.3(d) Joining multiple helically applied return tapes.

Page 57
B. Single longitudinal return tape.
Two methods are available for remaking a longitudinal return tape. The first is suitable for a
copper tape. A length of heavy copper wire braid is soft soldered to the ends of the return tape.
The braid may be a sleeve slipped over the cable before jointing began or may be a split sleeve.
The second method may be used for copper or aluminum return tape. The two ends of the return
tape are carefully cut to form them into a number of short tapes. Now a number of short tapes
are wound around the dielectric and spot brazed or pressure welded to these short tapes to
form the return conductor across the joint, in the same manner as for multiple helically
applied return tapes.
On completion of the return tape jointing, electrical testing is carried out to check continuity.
If the jointing of the return tape is faulty, it must be redone either partially if the area that is
faulty can be isolated or completely, if not.
As cables with this kind of return tape are normally jacketed to keep the return tape in place
on the dielectric this must be done before any completion of armor splicing can be completed.
Page 58
Soft Soft
Return soldered Braided soldered Return
Sheath tape joint sleeve joint tape Sheath
Soft Soft
Return brazed Copper brazed Return
Sheath tape joints tapes joints tape Sheath
Fig. 4.2.3.3.3(e) Joining single longitudinal return tapes.

Page 59
Stage 6 Figure 4. 2.3.3.3(f).
If the cable has a sheath over the return tape(s), it can be remade in three ways:
The first method consists of molding a new section of sheath between the ends of the cutaway
sheath. The joint is placed into an injection molding machine with a sheath mold of the correct
size, positioned, secured and tensioned and the mold closed and the molding carried out.
Because of the length of the molding and the relatively small thickness, considerable care must
be taken to ensure that the cable is correctly positioned in the mold. This technique can be
applied successfully only if the return conductor joints can be made tightly around the
dielectric and the joints can be kept to a low profile.
The second method is to use a section of sheath from a piece of spare cable. It is cut to length
and split longitudinally, then applied over the return conductor. It may be necessary to grind
out parts of the inside to get a good fit and allow the slit to close. It is then seam welded along
the split and the ends are joined to the ends of the cutaway sheath on the cable by two injection
moldings. This technique has the same type of restrictions as the first, but does not require
the very large molds.
The third method is to place a polyethylene sleeve on one end of the cable before jointing is
begun. When the return conductor has been jointed, it is packed with sections of sheath taken
from a piece of spare cable and then the sleeve is slid over the jointed area and also over both
of the ends of the cutaway sheath. The sleeve is then joined to the cable sheath by two injection
moldings. As the packing can be adjusted to accommodate bulky joints, this method is the most
flexible of the three.
To restore the hoop stress of a sheath, 1/16 inch - 1.5 mm galvanized iron wire is applied in a
tight, close-wound binding for a distance of about 5 feet - 1.5 meters over the joint.
If the cable is not externally armored ( armorless ) this completes the joining of the two cables.
If it is armored, the finishing of the armor splicing can now be carried out.
Page 60
Original sheath Remolded sheath Original sheath

first cable end over cut out section second cable end
Original sheath Injection Split sheath Injection Original sheath

first cable end molding seam welded together molding second cable end
Original sheath Original sheath

first cable end Sleeve second cable end
Injection Injection
molding molding
Fig. 4.2.3.3.3(f) Sheath restoration.

Page 61
4.2.3.4 Jointing Optical Conductors.
The jointing of ocean cables containing optical conductors is more complex than for electrical
conductors only. Jointing of the core, which includes the optical conductors, strength member
and electrical conductor is done by specialized Universal Jointing kit ( UJ ). The insulation is
restored by the normal injection molding. Optical ocean cables of different design, but with
same number of fiber pairs, can be joined with these kits and suitable cable end kits. Unlike
electrical conductor cable joints, the resulting joint is substantially larger in diameter than
the cable. For the deep sea cable, such as types LW and LWP, this requires that a boot be
placed over the joint to limit bending radii during transit through drum cable machinery and
sheaves. Similarly for the armored cable, the joining of the armor wires must have boots on each
end to limit bending radii.
4.2.3.4.2 Equipment.
Type Description
Universal jointing kit With end kits to suit ocean cable type(s).
Fusion splicer, jacket For optical fiber jointing.

stripper, ultrasonic
cleaner, fiber cleaver
X-ray machine Portable unit for cables including film, test pieces, processing
and viewing equipment.
Injection molding With mold(s) to suit insulation on ocean cable(s).

machine
Bend limiting boot Deep sea cables, type LW and LWP.
Armor terminations with Armored cables.

bend limiting boots
Other equipment required includes scissors, knife, lint free cloth, solvent, polyethylene slugs
for injection molding machine, heavy insulation stripping tool, armor cutting tools. The bend
limiting boots and armor terminations are to suit the cables being jointed.
Stage 1.
The two cable ends are on the cable working deck and the ends are prepared for jointing. For
the deep sea cables, the two halves of the bend limiting boot have been slid onto the two cable
ends, respectively. If the cable is armored, the outer servings, armor wires and armor bedding
has been unwound and tied back and surface of insulation cleaned, with the components of the
armor joint and bend limiting boots being slid onto each end as required.
Stage 2.
The two ends are now clamped to the jointing table. The Universal Jointing kit, shown in figure
4.2.3.4.3(a), is prepared for use.
Page 62
Components from the kit, including the bulkheads, pressure housing, polyethylene sleeve,
seals, etc. are slid onto the cable ends, for later assembly.
Optical fiber
mounting
Ferrule
Ferrule insert
Cage
Pressure housing
Bulkhead
Polyethylene sleeve
Load carrying
member
Fig. 4.2.3.4.3(a) Basic components of Universal Jointing Kit.
Next the polyethylene insulation is removed from end of each cable, exposing sufficient length
of the composite conductor for the joint. For each end, the copper conductor and the strength
member steel wires are cut to length, exposing the tube carrying the optical fibers.
These steel or nylon tubes are cut to length and the optical fibers are cleaned of the anti-
hosing compound (gel). If the optical fibers are wound around a king wire, the inner tube and
elastomer is removed to expose the optical fibers and the king wire, and the king wire is
terminated.
For each end, the steel wires of the strength member are crimped between two conical parts of
the ferrule assembly. If the tube around the optical fibers is made of steel, it is also anchored
to the ferrule.
The ferrules are now attached to the cage ready for the splicing of the optical fibers.
Page 63
Stage 3.
In the area where the splice will be made, the jacket, or coating, is first stripped from each
optical fiber in the matching pair, it is then cleaned in an ultrasonic cleaner, and finally cut to
length using a fiber cleaver.
The fiber pair is then placed into the fusion splicer and joined. The joint is then tested and if
the joint is acceptable, the next matching pair are done, if not, the splice is redone. The jacket
is remade over the area of the splice by micro-molding.
This is repeated until all the matching pairs are joined. The fibers are then made up into the
mounting and secured in place.
If the system is an unpowered one, then it may be possible to carry out transmission testing of
the joint at this point.
Ocean cable
Pressure housing
Ocean cable
Fig. 4.2.3.4.3(b) Universal Joint ready for overmoulding

to restore insulation.
Stage 4.
The components previously placed on the ends of the cables are now assembled, with the
exception of the polyethylene sleeve. The pressure housing is placed over the cage, and the
bulkheads and seals assembled on each end. The load carrying members and bolts are inserted
and torqued up. The resulting arrangement is shown in figure 4.2.3.4.3(b). The polyethylene
sleeve is now slid over the pressure housing.
Page 64
The resistance of the joint is measured between two points on the composite conductor a set
distance from each end of the joint, to check that continuity is acceptable ( typically < 0.2 ohms
). For powered systems, a high voltage test is applied over the joint.
Transmission testing can now be carried out to check the joint. If the system is a powered
system, it will be necessary to isolate the joint to protect personnel against possible high
voltages. If the joint is faulty, it can be disassembled readily at this point, as once the
injection molding is complete, it would be necessary to remake the entire joint if found faulty.
Stage 5.
The injection molding machine in now mounted on the jointing table and the insulation
restored. This is followed by visual and X-ray examination, If the molding is satisfactory, the
jointing is complete and the cable is ready for final transmission test. The form of the molding
over the splice is shown in figure 4.2.3.4.3(c).
There is an alternative method to the injection molding using heat shrink technology.
Fig. 4.2.3.4.3(c) Completed Universal Joint after insulation restored

with sprues from moulding process.
Stage 6.
Deep sea cables, type LW and LWP.
For the deep sea cable, the final stage is to install the bend limiting boot. The two ends of the
boot are slid up cable over the joint, and connected together, as shown in figure 4.2.3.4.3(d).
Page 65
Deep sea Bend limiting

cable boot
Universal
joint
Fig. 4.2.3.4.3(d) Deep sea cable splice.
Armored cables.
For the armored cable, the final stage is to mechanically join the armor wires from each end
and install the bend limiting boots. The method used is based on the terminations used for
repeaters, etc., as shown in Volume 7 of the Handbook, Appendix AA.5. Figure 4.2.3.4.3(e)
shows the Alcatel-Lucent armor joint. Considerable care needs to be taken when cutting armor
wires to length and the installation of the ferrules on their ends, and making up the rest of the
armor joint, to ensure that the full load is transferred between the two sets of armor wires
occurs, and not through the Universal Joint. The armored joint can also be used to joint two
different types of armor.
Universal Bend limiting

Ferrules
joint boot
Epoxy Cable jointing Armored

filler box cable
Fig. 4.2.3.4.3(e) Armored cable splice ( Alcatel-Lucent ).
N O T E : The description of the use of the Universal Joint kit is based in limited information
and is intended to provide information about this jointing method only. The Universal Joint is
an evolving technology and is likely to change as improvements are made.
Page 66
4.3 Splicing Armor Wires.
4.3.1 Overlaid Splice.
4.3.1.1 Introduction.
The overlaid splice is a method for joining conventionally armored ocean cable of the same
type. The completed splice results in a minimal increase in cable diameter, is only slightly
less flexible than the unspliced cable and can be handled in the same manner. Because of the
need to work the armor wires by hand, the method is generally only suitable for smaller armor
wires such as D or H. It is not suitable for cables with very small wires as these cannot form
the grip needed to transfer load.
4.3.1.2 Equipment.
Type Description.
Conductor joint- See section 4.2

ing equipment.
Splicing tool Tool for laying up armor wires, norm matched to cable type.
Typical form shown in figure 4.3.1.2(a).
Armor wire Wooden ring to support armor wires during rewinding, used to
guide prevent tangles and to allow splicing tool to work efficiently.
Other equipment required includes serving mallets, serving application tools, power circular
saws pliers, serving yarn and lashing wire, quick release hose clamps and clamps to hold cable
and work bench.
Page 67
Hinge
Left Right
half half
Handle
Notches for armor wires.

Retaining
Number of notches same
bolt
as number of armor wires.
Notches may be skewed to
Material: Steel match armor wire lay.
with hardened Diameter over notches
notches such that tool is sliding
fit over armor wires
Direction of
motion to lay
up armor wires
Fig. 4.3.1.2(a) Splicing tool for overlaid splice. ( Two required, one
for short end armor, and one for long end armor ).
Page 68
4.3.1.3 Procedure.
Stage 1 Figure 4.3.1.3(a).
The ends of the two cables to be spliced are brought into the cable working deck, and arranged
so they face one another.
The ends of each cable are first bound with insulating tape and cut off square with the circular
saw, to provide a clean end and a point to measure from.
One end is selected as the "short end". At 8 feet - 2.4 meters from this end, the outer servings
are bound and then stripped off-to expose the armor wires. These are then secured with a quick
release hose clamp next to the end of the outer servings.
The other end, the "long end". has the same operation carried out on it, except that the distance
the servings are stripped off is 40 feet - 12.2 meters.
Stage 2 Figure 4.3.1.3(b).
The armor wires are unlaid from each end and tied back out of the way. The armor beddings on
each and is bound with yarn as far up from the end as possible, and then unwound leaving the
cores bare.
The core of the short end is cut so that its length is 6 feet - 1.83 meters ( that is 2 feet - 0.6
meters in cut off ). The long end core is then cut so that its length is 4 feet - 1.2 meters ( that
is 36 feet - 11 meters is cut off ). There may be some modification of these lengths if there are
a large number of conductors as it will be necessary to stagger the joints in the individual
conductors to obtain as little increase in the diameter of the core as possible.
8 ft - 2.4 m 40 ft - 12.2 m
Quick release Exposed armor

Short end hose clips on Outer Long end
wires
armor wires servings
taped
Fig. 4.3.1.3(a) Preparation of cables for splicing.
6 ft - 1.83 m Unlaid 4 ft - 1.2 m

Short end armor Armor
wires bedding
Core Core
Armor Unlaid
bedding armor Long end
Yarn wires
binding
Fig. 4.3.1.3(b) Preparation of cores for jointing.

Page 69
Page 70
Stage 3 Figure 4.3.1.3(c).
The ends of the cables are now brought together and the core jointed. If the cable is multi-
conductor then the joints in the individual conductors are staggered to reduce the increase to
diameter of the core as much as possible. If the core is covered by tapes, or similar, these
should be relaid over the jointed area to give a smooth exterior.
Stage 4 Figure 4.3.1.3(d).
Using the armor bedding unwound from the short and, remake the armor bedding over the
jointed areas, and the rest of the exposed core. If this is insufficient to completely cover the
exposed core, then the unwound armor bedding from the long end is used to complete the cover.
Excess armor bedding from the ends should be cut off.
Short end Long end
Core jointed
Fig. 4.3.1.3(c) Jointing core.
Short end Long end
Armor bedding
rewound
Fig. 4.3.1.3(d) Rewinding armor bedding over core..

Page 71
Page 72
Stage 5 Figures 4.3.1.3(e) and 4.3.1.3(f).
The armor on the short end is rewound over the core using the splicing tool and armor wire
guide. Serving mallets should be used to ensure that the armor wires are properly seated on the
armor bedding. Yarn seizing should be applied about every 12 inches - 300 mm along the armor
wires as they are rewound to prevent unwinding. On completion, the quick release hose clips on
the short end are removed.
Armor
wire guide
Yarn seizing
Short end Armor Long end

Splicing wires
tool Armor
wires
Fig. 4.3.1.3(e) Rewinding short end armor wires.
Yarn seizing
Short end Rewound Armor Long end

armor wires
wires
Fig. 4.3.1.3(f) Short end armor wires rewound over core..

Page 73
Page 74
Stage 6 Figures 4.3.1.3(g), and 4.3.1.3(h).
The outer servings on the short end are now stripped back along the cable to expose the armor
wires over the length that the armor wires on the long end will overlap.
The armor wires on the long end are now rewound over the armor wires of the short end using
the splicing tool and the armor wire guides. Serving mallets are used to ensure that the armor
wires from the long end are properly seated on those of the short end.
Wire seizing is applied at regular intervals along the rewound armor wires of the long end, as
it is wound on, to prevent unwinding. On completion, the quick release hose clips are removed
from the long end armor wires.
Armor
wire guide Splicing
Armor wires
tool
Long end
Short end exposed
armor wires
Fig. 4.3.1.3(g) Rewinding long end armor wires.
Rewound
armor
wires Wire seizing
Short end Long end
Fig. 4.3.1.3(h) Long end armor wires rewound over short end.
Page 75
Page 76
Stage 7 Figures 4.3.1.3(i) and 4.3.1.3(j).
The entire length of the splice is now served with jute, jute/nylon, polypropylene or tarred
spun yarn using serving application tools to ensure that the armor wires are tightly bound. The
servings are covered with insulating tape ( cloth type ) to give a smooth surface and to reduce
the chance of the servings being caught during working.
Serving
applicatioon Insulating tape
tool
Short end Servings Long end
Fig, 4.3.1.3(i) Application of outer servings.
40 ft - 12.2 m
Fig, 4.3.1.3(j) Completed splice..

Page 77
Page 78
Blank page.
Page 79
4.3.2 Ring Splice.
4.3.2.1 Introduction.
The ring splice is a method of joining both conventional armored ocean cables and caged amour
ocean cables. The splice is not restricted to cables of the same armor type as the ring can be
made to accommodate a different size and number of armor wires in each of the cables being
joined, and can also be used for all armor wire sizes.
Figure 4.3.2.1(a) shows a typical completed ring splice. The swaged sleeves ( ferrules ) on the
armor wires transfer the load between the cables and the ring. The ring shown has two sets of
slots, one at each end, with the sleeves being contained in the middle section resulting in a
smaller diameter splice. The other form of the ring is larger, with all the slots on a single
periphery and the armor wires entering from both sides. This form results in a larger diameter
splice and is normally restricted to joining cables with the same number of armor wires, and of
the same size.
For the splicing of a cable with two layers of shore end armor, the outer layer is not terminated
in the ring, but is cut back a short distance from the splice and lashed. The primary function
of the outer layer is to provide wear resistance.
The completed splice can, in most cases, be worked through cable machinery and over sheaves
with care.
Page 80
Swaged sleeve
on armor wire
Wire support
cone Conductor
joint Outer
Servings of manila
servings
rope covered with
insulating tape
Cable Slot for Coupling Armor

core armor wire Keeper ring wires
Fig. 4.3.2.1(a) Compleed ring splice.

Page 81
4.3.2.2 Equipment.
Type Description.
Conductor jointing See section 4.2

equipment
Coupling ring To suit number and size of the armor wires in the cables being
with keeper joined, and conductor joint diameter.
Sleeves ( ferrules ) To suit number and size of the armor wires being joined.
Swaging tool(s) To suit sleeves.
Wire support cones Two, to suit cable and coupling ring, may be replaced by
building up servings.
Other equipment required includes serving mallets, serving application tools, portable band
saw, power circular saw, pliers, serving yarn. Manila rope, quick release hose clamps, clamps
to hold the cable, and work bench.
Notes:
A. The ring must have sufficient internal diameter to allow for the enlarged size of the
conductor carrying core due to the jointing of the conductors. Its strength must be sufficient to
take the breaking strength of smaller diameter armor wire cables, however, for large shore end
cables this may not be realistic and some restriction may be needed, typically 100 000 lbf. -
45 000 Kgf is the maximum strength designed for.
B. The procedure described assumes that the cables being joined are well known and the
measurements used for the splicing are known. It is possible to join cables without this
information. In stage 1, the armor wires are not cut back, but are fitted to the ring prior to the
swaging of the sleeves and any excess armor wire is then cut off. Care is required to ensure
that there is sufficient slack in the core to prevent it from being overstretched under load.
Page 82
4.3.2.3 Procedure.
Stage 1 Figure 4.3.2.3(a).
The ends of the two cables to be spliced are brought into the cable working deck.
The ends of the cables are first bound with insulating tape and cut off square with the circular
saw to provide a clean end and a point to measure from.
Hose clips are placed on each cable to hold the armor wires in place as the outer servings are
stripped off to expose the armor wires in the area to be worked in the splice. The armor wires
are then cut back using the portable band saw, the required distance from the ends of the
cables. This distance must be determined from tests on the cables to ensure that the completed
conductor joints are not overstretched as load is applied to the cable and the ring splice.
When both ends have been prepared, they are arranged so that they face one another.
Stage 2 Figure 4.3.2.3(b).
The keeper is slid over one end then the armor wires are unlaid from each end and tied back
out of the way. The armor bedding on each end is bound with yarn as far up from the end as
possible, and then unwound leaving the cores bare.
The coupling ring and one wires support cone are slid onto one cable end and the second wire
support cone onto the other cable end.
Quick release
Quick release
hose clips on
hose clips on
Exposed cores armor wires
armor wires
Exposed armor
wires
Fig. 4.3.2.3(a) Preparation of cables for splicing.
Unlaid armor
wires
Wire support Armor
Coupling bedding
cone
ring
Core
Armor Wire support

bedding cone Keeper
Unlaid armor
wires
Fig. 4.3.2.3(b) Preparation of cores for jointing.

Page 83
Page 84
Stage 3 Figure 4.3.2.3(c).
The ends of the cables are now brought together and the core jointed. If the cable is multi-
conductor, then the joints in the individual conductors are staggered to reduce the increase in
the diameter of the core as much as possible. If the core is covered with tapes, or similar, then
these should be relayed over the jointed area to give a smooth exterior.
Stage 4 Figure 4.3.2.3(d).
The coupling ring is now positioned over the center of the splice and the wire support cones
slid up on either side. The armor bedding is remade on one side up to the wire support cone.
On the side where the armor bedding has been remade, the armor wires are now splayed out and
the sleeves are swaged onto the end of the wires.
Core
jointed
Fig. 4.3.2.3(c) Jointing core.
Coupling and wire support

Sleevees swaged cones over core joint
to end of each
armor wire
Armor wires
splayed out
Fig. 4.3.2.3(d) Preparation of first end armor wires.

Page 85
Page 86
Stage 5 Figure 4.3.2.3(e).
The armor wires with the swaged ferrules are now relaid on the cable and the ends placed into
the slots on the coupling ring. A light tension is applied when all armor wires are in place to
seat the sleeves.
Stage 6 Figure 4.3.2.3(f).
The armor bedding on the second side is now remade and the armor wires splayed out. To check
the position of the sleeves, one wire is relaid on the cable and into a slot on the coupling ring.
If this is in the correct position, this wire is again unlaid and the sleeves are swaged onto all
the armor wires. If not, then the necessary adjustments must be made to ensure a correct
splice, before proceeding.
Armor wires relaid and
inserted into slots on
coupling ring
Fig. 4.3.2.3(e) First end armor wires completed.
Armor wires
splayed out
Sleeves swaged
to end of each
armor wire
Fig. 4.3.2.3(f) Preparation of second end armor wires..

Page 87
Page 88
Stage 7 Figure 4.3.2.3(g).
The armor wires on the second side are now relayed on the cable and the ends placed into the
second set of slots on the coupling ring. The light tension is now applied across the splice to
seat all armor wire sleeves. The keeper is now slid up the cable and screwed home on the
coupling ring and locked in place.
Stage 8 Figure 4.3.2.3(h).
The outer servings are now remade up to the coupling ring from both sides to provide a smooth
surface and to further aid in the location of the armor wires in their respective slots.
Finally, the whole splice is served with 3/8 to 1/2 inch - 10 to 13 mm diameter Manila rope to
provide protection for the splice and this is covered with insulating tape.
Armor wires relaid and inserted into
slots on coupling ring. Keeper screwed
home and locked in position
Fig, 4.3.2.3(g) Second end armor wires completed.
Serving of manila rope covered

with insulating tape
Fig, 4.3.2.3(h) Completed splice.

Page 89
Page 90
4.4 Times to Carry Out Jointing and Splicing of Ocean Cables.
The times to carry out jointing and splicing of ocean cables depends on many factors, varying
from the condition of the cables, the amount of experience that the personal have had working
the cables the sea conditions, etc.
The following are given as a guide for times based on experienced personnel and the cables in
good condition.
Coaxial center strength member ( armorless ) ocean cable, deep sea type - 5 to 6 hours (1.5
inch diameter ).
Coaxial ocean cable, shore end type, single armor - up to 12 hours ( 1.5 inch diameter ).
Optical conductor ocean cables deep sea type - 6 hours ( TAT 8 ).
Multiconductor core jointing - quad - 1/2 hour preparation, 1/2 hour per quad, 1/2 hour to
finish, using one injection molding machine only.
Armor splicing, overlaid splice - preparation prior to jointing of conductors ) 1/2 to 1 hour,
both ends done simultaneously; splicing 1-1/2 to 3 hours depending on armor wires size and
number.
Armor splicing, ring splice heavy armor - preparation ( prior to jointing of conductors ) 1 to
2 hours, both ends done simultaneously; splicing 1/2 to 1 hour setting up, 5 minutes for each
ferrule to be swaged on an armor wire, 1 to 2 hours to finish.
Annexes.
Page A1
A. Electromagnetic Field Around Ocean Cables.
A.1 Overview.
A standard method of locating an ocean cable and a fault ( conductor grounded to sea ) is to
measure the electromagnetic field caused by a test signal applied to the cable ( the standard
frequency is 25 Hz ). For a given system, the strength of the generated field is dependent on
the ocean cable and the repeater characteristics. This section gives a method for calculating
these fields ( in terms of net cable current ) for faults at various distances from the shore.
Hence for a given measuring system sensitivity ( and a given ocean cable system ), the
maximum distance from the shore at which the location of the ocean cable and the fault can be
determined.
A.2 Wave-guide Analysis for Symmetric Ocean Cable.
The electromagnetic field propagating along a cable is governed by Maxwell's equations which,
when expressed in cylindrical coordinates ( r,",z ). become:
1 #
r H = %' j & E z (A.2-1)
r #r $
!
# Ez
' j( z Er ' = ' j & H$ (A.2-2)
#r
!
j ( z H$ = %' j & E r (A.2-3)
! where the field dependence on time t and longitudinal distance z is assumed to be

exp ( j & t ' j ( z z ) , all fields are independent of azimuthal angle " and
!
%' =% + ) j & (A.2-4)
! !
! where
!
!) = conductivity
= permeability
% = permittivity
! Equations A.2-1, A.2-2, and A.2-3 relate to the three field components H$ ,E r , and Ez which
! comprise the cylindrically symmetric TM modes, which are the only propagating modes at the
! low frequencies of interest.
Eliminating the electric fields from equations A.2-1, A.2-2, !

and A.2-3 yields
! the following
equation for H$
* # 1 # 2
-
, r + (r / H$ = 0 (A.2-5)
! + #r r #r .
!
Page A2
where
1
2
(
( r = & 2 %' '( z ) 2
Im ( ( r ) > 0 (A.2-6)
The general solution of equation A.2-5 is:
! H$ = A J 1 ( ( r r ) + BY 1 ( ( r r ) (A.2-7)
where J1 and Y1 are Bessel functions and A and B are arbitrary constants. Ez can now be
derived:
!
(r
! ! E z =
%' j &
( A J0 ( (r r) + BY!0 ( ( r r) )! ! (A.2-8)
A coaxial cable consists of a number ( N ) of homogeneous cylindrical layers in which the

electromagnetic fields take the form given in equations A.2-7, A.2-8, and A.2-3, with A,B,( r ,
! and %' assuming different values in each layer. The constants A and B in each layer of the N
( )
layers are constrained to satisfy the 2 N '1 boundary equations of continuous H$ and E z at
!
the N '1 cylindrical interfaces. Furthermore, the requirement that the solution be finite at
!
r =0 and r =0 implies B= 0 in the central region !and B=!j A in the outermost layer. These
! !
2N constraints imply 2N linear equations that the 2N amplitudes A and B must satisfy. To
! ! 2N 1!2 N matrix of
permit a solution, ( z must be chosen so that the determinant of the
! coefficients vanishes.
! ! ! !
! ! such eigenvalues
The number of (z !
corresponding !
to propagation !modes equals the number of
insulating!layers. If the conductors ( including the seawater )!are perfect, this equality is
clear, for electromagnetic waves can propagate in each insulating layer independently, each
layer is therefore supporting its own single propagating TM mode. If conducting layers have
finite conductivity, the!wave-guides are no longer independent, since electromagnetic waves
can penetrate the conductors, but the number of modes remains the same. In this case the
modes overlap spatially but differ from one another in relative distribution of energy among
the various insulating layers as well as in their longitudinal wave number ( z .
Table A.2(a) gives values for use in analysis of coaxial, or similar, ocean cables.
!
Table A.2(a)
Values for Use in Wave-guide Analysis of Ocean Cables.
Material Conductivity
mhos/foot mhos/meter
_____________________________________________
Copper 1.8 x 107 5.9 x 107
Steel 1.46 x 106 4.8 x 106
Sea water 1.22 4

_____________________________________________
Page A3
Table A.2(a) ( Continued )
Values for Use in Wave-guide Analysis of Ocean Cables.
Material Permittivity Permeability

_____________________________________________
Polyethylene 2.285 %0
Sea water 81 %0
Steel 180 0
_____________________________________________
!
%0 = Permittivity of free space.
!
0 = Permeability of free space. !
! The attenuation length for a given mode is defined as ' 1 Im ( ( z ) .

!
A.3 Transmission Line Analysis.
! cable with conductors ( N = 2 for armorless

To predict signal propagation along an ocean
coaxial ocean cable, N = 3 for single armored coaxial ocean cable ), the appropriate amplitudes
of the 2N modes ( N types of modes, two directions of propagation ) must be calculated for
each repeater section. The superposition of these modes must satisfy the relevant boundary
conditions ( expressed as constraints on voltages and currents )!
at each end of the section. This
!
analysis requires an equivalent circuit for the repeater, such as shown in figure A.3(a). The
! !
repeater equivalent impedance depends strongly on whether DC power is applied. The ocean
cable's outer conductor ( for coaxial ocean cable ) and armor wires ( if present ) are grounded
to sea at each repeater, as shown.
The solution of the transmission line analysis requires matrix manipulation. The procedure
starts at the offshore break, where all N conductors are grounded to sea. These N constraints
on the mode amplitudes, along with N '1 constraints that all conductors except the center
conductor are grounded to sea at the offshore end of the most offshore repeater, provide 2N ' 1
constraints on the 2N modes propagating in the last cable section ( ie. the one between the last
! !
repeater and the cable break ). The relative amplitudes of these modes can therefore be
determined, leaving only an!arbitrary multiplicative constant ( common to all modes ) to be
adjusted later. These mode amplitudes can be manipulated to provide the voltage
! and current at
the offshore
! port of the last repeater, and conventional circuit analysis then provides the
voltage and current at the shoreward port. These values of voltage and current provide two
constraints on the 2N modes in the next shoreward ocean cable section, with the other 2N ' 2
constraints coming from the fact that all conductors but one ( the center conductor ) are
grounded to sea at both ends of the ocean cable section. The 2 mode amplitudes in the next-to-
last ocean cable section can therefore be found.
! !
In this way the solution is propagated from the cable break back toward the shore terminal,
with mode amplitudes being determined in each ocean cable section so that the appropriate
constraints on voltages and currents are satisfied at the cable break and at both ports of every
repeater. Once the solution is complete, it is adjusted by a multiplicative constant so as to
satisfy the driving point condition ( e.g. that the center conductor current be a certain value at
Page A4
the shore terminal, such as 200 mA ).
Ocean cable Repeater Ocean cable
R1
Inner
conductor
Outer C1 C2
conductor
!
Armor wires
(if present)
!
Sea ground !
Example - SG repeater
R1 = 116 5 Unpowered
= 18.3 5 Powered
C 1 = 32 F
C 2 = 0.026 F
Fig. A.3(a) Typical equivalent circuit for coaxial repeater.
The normal driving frequency for fault determination is 25 Hz. Figures A.3(b) and A.3(c) show
propagation in the SG coaxial ocean cable with repeaters at 5 n. mile intervals for various
distances to offshore breaks, with the repeaters unpowered and powered respectively. As can
be seen, the major cause of signal loss occurs in the repeaters, rather than losses in the ocean
cable. The powering of the repeaters for this system allows breaks to be found further offshore
for the same sensitivity in detecting equipment.
These figures are for unarmored ocean cable. The effect of armor is to provide a shielding effect
reducing the net current on the armored ocean cable. In the SG coaxial ocean cable with A
armor, the net current in the armored cable is about 40% of that in the unarmored cable. This
ratio is about equal to the quantity
= exp( ' 2 3 4) (A.3-1)
where
! 23 = Thickness of armor layer.

1
2
4 = ( 2 & ) ) the skin depth in steel.
! The attenuation of the signal with distance offshore, being governed primarily by the
repeaters, is the same for both armored and unarmored ocean cable ( for SG system ) for all
! !practical purposes.
Page A5
Hence for a given system, with sections of armored and unarmored ocean cables calculations
can be done for the ends of the trunk to determine the distance out from the shore terminal that
the available detection equipment ( shipboard or ROV ) will be effective in detecting a cable
break for use in planning repair operation procedures. If the system has a longer spacing
between repeaters and the ocean cable has higher losses than the SG system used as an example,
the effect of the ocean cable could become more significant.
180
160
Net cable current in milli-amperes
140
Break at 50 n.m.
120
100
80
60
Break at 100 n.m.
40
20 Break at 150 n.m.

Break at 200 n.m.
0
0 20 40 60 80 100 120 140 160 180 200 220
Distance offshore in nautical miles
Fig. A.3(b) Propagation of 25 Hz signal, unarmored

SG ocean cable with cable breaks at
various locations. Center conductor
current 200 mA at shore point,
repeaters unpowered.
Page A6
180
Break at 50 n.m.
160 Break at 100 n.m.
Net cable current in milli-amperes
140
120
Break at 150 n.m.
100
80
Break at 200 n.m.
60
40
20
0
0 20 40 60 80 100 120 140 160 180 200 220
Distance offshore in nautical miles
Fig. A.3(c) Propagation of 25 Hz signal, unarmored

SG ocean cable with cable breaks at
various locations. Center conductor
current 200 mA at shore point,
repeaters powered.
Page A7
B. Cable Repair ROV's
B.1 Introduction.
The need for ROV's to be used in cable repair became necessary after the introduction of cable
burial for protection of ocean cables against increasing bottom activities such as trawling.
While grappling of buried ocean cables can be done using detrenching grapnels, this often
involves severe strain on the ocean cable as it is pulled from the bottom and it is not possible
to immediately re-burying the ocean cable after the repair is complete, leaving it vulnerable to
damage.
Ocean cables, and repeaters, are typically buried about 6 to 8 feet - 2 to 2.5 meters at the
shore end and out to the outer extent of the surf zone. Beyond the surf zone they are typically
buried at about 4 feet - 1.2 meters out to 0.5 n. miles - 1000 meters depth. Due to fishing
activities in some areas going into deeper water, burial is being extended to 1 n. mile - 2000
meters depth in these areas.
There several types of cable repair ROV in service, and they follow the same design concept but
differ in the way some operations are carried out. Due to the similarity between these ROV's,
the SCARAB is described in some detail while the general characteristics of the CIRRUS only
are given.
Over time the cable repair ROVs are replaced with more capable units, able to work in stronger
currents, deeper depths, and able to bury cable to deeper depth into the bottom and uncover it
for repair.
The cable repair ROV's are also used for cable burial after laying and for inspection of ocean
cable.
B.2 Cable Repair ROVs in Service.
Most of cable repair ROVs in service are under Maintenance Agreements. This ensures that
each communications ocean cable system has access to a ROV to ensure that repairs and
inspection can be carried out on buried sections of the system.
Companies in these agreements are required to undertake the acquisition, retrieval, repair and
burial operations in less than ideal weather conditions to minimize the downtime of a damaged
system.
The ROVs in these agreements are required to have an integrated cable locating system that
perform actively using a 25 Hz tone applied to the ocean cable, or passively using magnetic
tracking ( see Annex A ).
Table B.2(a) gives the characteristics of some of the cable repair ROVs in the agreements.
There is a small number of cable repair ROVs outside of maintenance agreements that are used
for non-communications systems, such as ranges, surveillance systems, etc.
Page A8
Table B.2(a)
Characteristics of Some Cable Repair ROVs.
SCARAB SCARAB SCARAB MARCUS MARCUS CIRRUS

Vehicle ROV-128
III IV ONE II III B
Horsepower 180 150 180 150 240 804 100
Designer Slingsby ISE Slingsby ISE SMD SMD Slingsby
Tool design Slingsby Oceaneering Slingsby Oceaneering SMD SMD Slingasby
Weight
8512 6000 8512 10500 3550 33000 3000
lbs
Umbilical 2500
2800 2350 2800 3200 3300 1200
(meters) (depth)
Speed
3.1 3.5 3.1 3.9 3.0 3.0 3.0
(knots)
Jetting
600 m/hr 520 m/hr 100 m/hr 560 m/hr 1000 m/hr - 100 m/hr
speed
Bollard pull
1325 lbf 1500 lbf 1325 lbf 1700 lbf 3740 lbf - 1325 lbf
forward
Soil shear
High High High High Medium High -
strength
Soil elast-
icity KPa
200 100 100 100 100+ - -
Telemetry
Slingsby GESPAC Slingsby GESPAC SMD SMD Slingsby
system
Cable
Slingsby INNOVATUM Slingsby INNOVATUM KDD KDD Slingsby
tracking
Cable INNOVATUM INNOVATUM

TSS
TSS planned
TSS
TSS planned
N/A - TSS
locator
4 x SIT, 2 4 x SIT, 2
Cameras 3 x SIT 3 x SIT 5 x Cam. 5 x Cam. 5 x Cam.
color CCD color CCD
B.3 Description of Cable Repair ROVs.
B.3.1 SCARAB
B.3.1.1 Development.
The SCARAB ( Submersible Craft Assisting Repair And Burial ) ROV's were the first cable
repair ROV's and have undergone considerable development during their life ( SCARAB I, II,
III, IV and ONE ). The system is designed to be portable by air and require little modification
to a support vessel to allow its use. The support vessel is normally a cable ship for repair
operations, and for post laying burial can be a suitable craft of opportunity. ROV-128 is
related to the SCARABs (CHECK)
Page A9
B.3.1.2 Characteristics.
The major characteristics of the SCARAB I and II systems are given in table B.3.1.2(a). Figure
B.3.1.2(a) shows the arrangement of the vehicle.
The SCARAB I vehicle can uncover 30 ft - 10 meters of ocean cable buried at 4 ft - 1.2 meters
depth in about 15 minutes using its dredger nozzle. It can re-bury cable, including coiled or
tangled cable, to a depth of 2 ft - 0.6 meters at about 500 ft - 150 meters per hour on slopes up
to 30%. Uncovering and re-burying rates are dependent on the nature of the bottom material.
In the case of failure of the umbilical cable, the SCARAB vehicle will rise to the surface and is
fitted with a strobe flasher, radio beacon and acoustic pinger with a 30 day life for vehicle
location. If it does not rise to the surface, the broken umbilical cable can be grappled for.
Umbilical cable Vertical thrusters

Latch assembly 35 HP motor
Sonar
Flotation
tanks
Lights
Magnetometer
Starboard
T.V. camera
Port
thrusters
Dredge and
jet pumps
Manipulators
Port gradiometers
Cable
cutter Magnetometers
Port frame splices
Cable
clamp
Fig. B.3.1.2(a) SCARAB I vehicle.

Page A10
Table B.3.1.2(a)
SCARAB I & II Characteristics.
Operating depth: 6000 ft. - 1829 m.

Dimensions ( L x W x H ): 132 in. x 72 in. x 60 in. - 3350 mm x 1830 mm x 1520 mm.
Weight: Dry: 5000 lbs. - 2268 Kg.
Speed: (max. surface ) 3 knots.
(max. operating current ) 0.5 knots at 6000 ft - 1830 meters.
Structure: Open tubular framework enclosing and supporting vehicle
components.
Buoyancy: Cylindrical flotation tanks providing 50 lbs. of positive
buoyancy when submerged.
Power requirements: 480 VAC 3-phase 150 Kw. Portable diesel ( 2 ea. fully
redundant ) electric generators supply all power requirements.
A 10000 ft. - 3048 m long umbilical cable 1.4 in- 36 mm. dia..
powers and controls the vehicle.
Propulsion: Six, 5 hp each, electric motor thrusters, two vertical and four
fore-aft. One 5 hp hydraulic motor thruster athwartships. All
individually controllable.
Instrumentation: Two low light level TV cameras ( one with zoom ) on pan and tilt
units, one 35 mm still camera, lights, bottom contour following
sensors, altimeter, depth sensors, total field and component (
vector ) magnetometers ( for cable location ). Two hydraulically
powered manipulators, 5 degree-of-freedom, equipped with
devices for cutting and gripping ocean cables. 35 hp dredge or
jet pump to uncover or bury ocean cables.
Navigation: 360 degree CFTM sonar, capable of interrogating bottom
mounted acoustic transponders and locating pingers for relative
bottom positioning. Beacon on vehicle for use with computer
driven graphics display tracking unit on support vessel for
obtaining vehicle relative range and bearing.
Shipboard components: Hut with power distribution unit, control/display console and
navigation plotter; spare parts;
2 diesel generators, umbilical cable, cable floats, vehicle.
location unit and motion compensated launcher with cable
stowage reel.
Support vessel requirements: Deck space for shipboard components and vehicle, mounting
pads for launcher.
Operation/maintenance crew: Operator, assistant operator, and observer.
Total shipping weight.: 94000 lbs - 42638 Kg.
Total shipping volume; Nine standard air freight containers hold all components.
Volume of each container ( LD-3 ) is 158 cub. ft. - 4.8 cub. m.
Builder: AMETEK/Straza El Cajon California USA.

Page A11
The characteristics of the SCARAB IV is given in table B.3.1.2(b). SCARAB III and ONE are of
similar characteristics, but have been designed for use in other areas and have differences to
suit the conditions found in these areas. Figure B.3.1.2(b) shows the SCARAB IV and its
handling crane.
Table B.3.1.2(b)
SCARAB IV Characteristics.
Operating Depth: 6060 feet -1850 meters.

Dimension ( L x W x H): 157 in x 79 in x 79 in - 4000 mm x 2000 mm x 2000 mm.
Weight: 6000 lbs - 2730 Kg.
Speed: 3.5 knots.
Structure: Open framework enclosing and supporting vehicle components.
Buoyancy: Flotation units providing positive buoyancy when submerged.
Power requirements: 2300 VAC 3-phase. Portable diesel ( 2 ea. fully redundant )
electric generators supply all power requirements.
A 7700 ft. ( 2350 m ) long umbilical cable powers and controls
the vehicle.
Propulsion: Two fore-aft, two lateral, and four vertical thrusters. All indiv-
idually controllable.
Instrumentation: Five low light level TV cameras on pan and tilt units, lights,
bottom contour following sensors, altimeter, depth sensors, total
field and component ( vector ) magnetometers ( for cable location
). Two hydraulically powered manipulators, 5 degree-of-freedom,
equipped with devices for cutting and gripping ocean cables,
able to mounted on vehicle or jetting sled. Dredge, high-volume
venturi or jet pump for use with manipulators to uncover or bury
ocean cables.
Removable jetting sled subsystem for burying or uncovering
cables. Three pairs of of high-volume, low-pressure nozzles,
three pairs of low-volume, high-pressure nozzles, and two
excavation nozzles. Each pair of nozzles able to be deployed
independently.
Navigation: 360 degree CFTM sonar, capable of interrogating bottom
mounted acoustic transponders and locating pingers for relative
bottom positioning. Beacon on vehicle for use with computer
driven graphics display tracking unit on support vessel for
obtaining vehicle relative range and bearing.
Shipboard components: Control van, 2 diesel generators, umbilical cable winch and
power pack, vehicle location unit and motion compensated
articulated crane launch and recovery system.
Support vessel requirements: Deck space for shipboard components and vehicle, mounting
pads for launcher.
Status operational.
Builder: ISE.
Page A12
Fig. B.3.1.2(b) SCARAB IV ROV on launch-and-recover

knuckleboom crane.
B.3.2 CIRRUS.
The CIRRUS ROV was developed from the SCARAB I ROV but used later technology which makes
it more flexible than the original SCARAB's. The system is designed to be portable but
requires a support vessel fitted to take the equipment. For cable repair this support vessel is
normally a cable ship.
The major characteristics of the CIRRUS system are given in table B.3.2.2(a). Figure B.3.2.2(a)
shows the arrangement of the vehicle.
The other characteristics of the CIRRUS system are basically similar to those of the SCARAB
system.
Page A13
Table B.3.2.2(a)
CIRRUS Characteristics.
Operating depth: 3280 ft. - 1000 m.

Dimensions ( L x W x H ): approx.: 110 in x 66 in x 70 in - 2795 mm x 1680 mm x 1780 mm
Weight ( Dry ):
Speed: ( max. surface ): 3 knots.
( depth ) : 0.75 knots at 3000 ft - 915 meters.
Structure: Open framework enclosing and supporting vehicle components.
Buoyancy: Modular flotation tanks providing positive buoyancy when
submerged.
Power requirements: VAC 3-phase. Portable diesel ( 2 ea. fully redundant )
electric generators supply all power requirements. A ft. ( m )
long umbilical cable in. dia, powers and controls the vehicle.
Propulsion: Five hydraulic motor thrusters, two vertical, two fore-aft, and
one athwartships. All individually controllable.
Instrumentation: Five TV cameras ( one color ) some on pan and tilt units,
lights, bottom contour following sensors, altimeter, depth
sensors, component magnetometers C for cable location ). Two
manipulator arms with general purpose claw grips, with
accessories for cable cutting and gripping, and jetting unit to
unbury ocean cables. Cable burial tool for burying ocean cables.
Navigation: 360 degree obstacle avoidance sonar, capable of interrogating
bottom mounted acoustic transponders for relative bottom
positioning. Beacon on vehicle for use with computer driven
graphics display tracking unit on support vessel for obtaining
relative range and bearing.
Shipboard components: Support module ( hut ) with power distribution, control/display
console and navigation plotter; spare parts; 2 diesel generators;
cable; cable floats; vehicle location units and
launching/recovery crane with cable stowage reel.
Support vessel requirements: Deck space for shipboard components and vehicle(s)s and base
for launching/recovery crane, operation/maintenance crew:
operator, assistant operator.
Status: CIRRUS operational.

Builder: SEL.
Page A14
Umbilical control cable
Obstacle
avoidance
Acoustic
sonar
beacon
Reversible
hydraulic
thrusters 5 television
cameras
2 independent
50 HP hydraulic
systems
Cable burial tool
Magnetometer
system Manipulator arms
Jetting tool
Fig. B.3.2.2(a) CIRRUS vehicle.
B.3.3 Cable Repair System ( CRS )
The Cable Repair System ( CRS ) was developed from the HYDRA AT 1850 vehicle for the U.S.
Navy.
The CRS are free swimming ROVs, controlled by an umbilical to the Tether Management System (
TMS ). The neutrally buoyant umbilical allows the vehicle to operate up to 600 feet - 180
meters from the TMS. This design differs from the above cable repair ROVs, in that the CRS
vehicle only has to drag around a relatively short umbilical, rather than a long one going to the
surface. The characteristics of the CRS I & II systems are given in table B.3.3.2(a), and the
vehicle and TMS are shown in figure B.3.3.2(a).
Page A15
Table B.3.3.2(a)
CRS I & II Characteristics.
Operating depth: 6000 feet - 1830 meters.

Dimensions ( L x W x H ): Vehicle - 10 ft x 6 ft x 6 ft - 3048 mm x 1830 mm x 1830 mm.
Tether management system - 10 ft x 5 ft x 6 ft -
3048 mm x 1525 mm x 1830 mm.
Weight: Vehicle - 9000 lb - 4090 Kg.
Vehicle + TMS +Jetter - 13000 lb - 5900 Kg.
Speed: 5+ knots.
Structure: Open frame t6061 aluminum alloy, stainless steel fixtures.
Buoyancy: Syntactic foam flotation units provide positive buoyancy when
submerged.
Power requirements: 460 VAC, 3-phase, 60 Hz.
Propulsion: Six hydraulic thrusters, two forward/reverse, two vertical, two
lateral.
Instrumentation: Vehicle: two TV cameras on pan/tilt devices, scanning sonar, two
manipulators - 7 function, depth sensor.
TMA: TV camera on pan/tilt device, 5 lights.
Tools: Jetting skid, shear cutters for wire rope and soft line,
wire gripper.
Navigation: Fluxgate compass, acoustic navigation system.
Shipboard components: Control console,hydraulic power unit, surface handling system.
Status: Operational.
Builder: Oceaneering International Inc.
Page A16
Fig. B.3.3.2(a) Cable Repair System ( CRS ), showing vehicle

and tether management system ( TMS ).
Page A17
B.4 Operation of Cable Repair ROV.
B.4.1 General.
The following general description of the operation of cable repair ROVs is based on a
description of the original SCARAB vehicle, with some additions from later information. As
most cable repair ROVs are basically similar in characteristics, this description should cover
their operation as well.
B.4.2 Operator Displays and Controls.
The systems requires typically three crew to control them during operations on the sea floor,
an operator, an assistant operators and an observer. All crew and equipment are housed in an
portable operator control hut.
For the SCARAB system, the primary display for the operator is a display panel driven by the
system computer. The display can be set to several formats. The first, shown in figure 5.2.3(b),
is the estimated cable location in the plan view relative to the vehicle's position. This shows
the outline of the vehicle's, perimeter, estimated cable track and cable current, averaging time,
vehicle heading, height of the vehicle above the cable ( AC detection ). The computer examines
the cable location estimates as they are calculated and compares them to the preceding ones. If
they are not consistent, then they are not displayed. This aids the operator when the vehicle is
far from the cable by not displaying false data.
At the bottom of the display, a history of the depth of burial of the cable can be shown. This is
determined by subtracting vehicle height above the sea floor from the estimated height of the
vehicle above the cable. To reduce the effect of noise, a larger time averaging period can be
selected. A more accurate burial depth can be gained by setting the vehicle on the sea floor
which removes the noisy height above the sea floor component.
ESTIMATED SCARAB!S
CURRENT (mA) NORTH TRUE HEADING
40. 072
1 SEC.
DATA
AVG.
WEST EAST
SOUTH
BURIAL
DEPTH 0
3 SEC
AVG. 1
60 SECONDS
Fig. B.4.2(a) First display format.

Page A18
A second display format, shown in figure B.4.2(b), gives a history of the three magnetic field
components of a single magnetometer, selected by the operator. This display is useful for
trouble shooting ( e.g. finding a faulty magnetometer ), or when the vehicle is some distance
away from the cable, either outside cable location range, or when the cable current is too weak
for the localization algorithm to operate.
SIGNALS FROM MAGNETOMETER No. 1

FWD 4 SCARAB!S
TRUE HEADING
0 072
AFT 1 SEC.
-4 DATA
PORT 4 AVG.
STBD -4
UP 4
DOWN -4
60 SECONDS
Fig. B.4.2(b) Second display format.
A third display format is of the output from the gradiometer for DC detection of the cable.
The other displays for the operators are for the TV cameras on the vehicle, the scanning sonar
and navigation system. Operator controls include vehicle maneuvering ( thrusters ),
manipulator arms, TV camera panning and tilting, and cable dredging and burial pumps.
B.4.3 Operation of the Vehicle.
The cable ship on arriving at the estimated position of the cable fault, positions herself
shoreward of the fault and relatively near the cable route ( though not so near that the
direction of the cable is ambiguous ). The vehicle is launched and descends to the sea floor. It
then proceeds on or close to the sea floor at about 1 knot, on a course that will cross the cable
at right angles, with the operators monitoring the computer display for the cable's presence.
At between 50 and 100 feet - 15 to 30 meters from the cable, the 25 Hz signal will start to rise
out of the noise. As the cable is crossed, the characteristic signature will be seen on the
magnetic field history display ( AC detection ). The operator then turns the vehicle back
toward the cable, intersecting it obliquely, and swimming directly above it towards the fault,
using the plan view display mode to facilitate tracking.
Except in severe ocean currents, the vehicle should be able to stay within 10 feet - 3 meters of
the cable track, so the restricted range of the localization algorithm in the computer should be
operable. Gentle bends in the cable should not effect the tracking algorithm adversely, as long
Page A19
as the radius of curvature is large compared with the dimension of the magnetometer array.
Sharper bends will normally be unburied, therefore causing no confusion if visibility is
adequate. If the cable current is less than about 10 mA RMS near the fault, it may be
insufficient for the tracking algorithm to operate. In this case the magnetic field history, or
passive detection, display mode can be used, either steering so as to maintain zero vertical
field component, or by zigzagging across the cable, ascertaining from the display each tine the
cable is crossed.
Another system that can be used to detect the cable, if fitted to the vehicle, is parametric
sonar. For small diameter ocean cables, the magnetic field may be very small, making passive
magentic detection difficult. This sonar uses digital pulse chirps, which are capable of
penetrating the bottom and locating the cable.
When the fault is reached, it may very well be recognizable visually, either because the cable
was pulled out of the bottom when it was broken or because the source of the damage such as a
trawler otter boards, left visible tracks on the sea floor. If there is no visual indication, the
fault location may be recognized by the sudden decrease in the magnetic field, causing a
deterioration of the cable location estimate as the fault location is passed, along with a sudden
decrease in estimated cable current. This effect results from the nature of the field near the
faulted end of the cable where the magnetic field falls to zero in a horizontal distance
comparable to the vertical distance of the vehicle above the cable ( ie. about 3 feet - 1 meter or
2 seconds at a vehicle speed of 1 knot ). With the realization of passing the fault, the operator
can circle back, reacquire the cable and position the vehicle on the sea floor near the fault,
perhaps recognizing the precise fault location by the fact that when the vehicle is directly over
the fault, the magnetic field ( and hence the estimated cable current ) will have fallen to half
the value it had before the area of the fault was reached.
Fig. B.4.3(a) Unburying ocean cable using dredger jet.

Page A20
Once the vehicle is on the sea floor at the fault, its dredger, excavation or venturi, nozzle(s) is
used to uncover the ocean cable sufficiently to allow access for the vehicle's tools to be used, as
shown in figure B.4.3(a). The proper nozzle deployment configuration and nozzle deployment
depth for jetting, based on the soil type, can be selected using the computer.
Fig. B.4.3(b) Cutting ocean cable.
If the cable has not been broken it will be necessary to cut it through so that the ends can be
raised separately to the surface, as the cable was laid with zero excess slack. This is done
using the cutter as shown in figure B.4.3(b). Cable cutters can normally cut up to 4 inch - 100
mm dia. double armored ocean cable.
Page A21
Fig. B.4.3(c) Placing clamps on ocean cable.
The next stage is to place the cable grippers on the ocean cable on either side of the fault or
cut, as shown in figure B.4.3(c). Once applied to the cable, the grippers are ejected to free them
from the vehicle. An acoustic pinger or transponder is now normally laid on the sea floor near
the fault as a reference point. Cable grippers and clamps can normally grip smaller optical
ocean cables ( 1 inch - 25.8 mm ).
Page A22
Fig. B.4.3(d) Attaching lift line to clamp.
A lift line must now be attached to one of the grippers. The line can be clipped to the umbilical
cable, lowered from the cable ship, or be attached to the mooring of a balloon buoy laid at the
beginning of the repair operation. The line is attached to the gripper, as shown in figure
B.4.3(d) and after the vehicle moves away, the line is recovered bringing with it the end of the
ocean cable. In some cases the vehicle may have to uncover more cable to allow the end to be
lifted without causing excess strain on the cable. The process is repeated for the other end (
noting that only one lifting line can be clipped to the umbilical cable ) and the
pinger/transponder recovered.
Page A23
Fig. B.4.3(e) Re-burying ocean cable.
The cable ship then carries out the repair,in the normal manner, however since the ocean cable
was laid with zero excess slack, an additional length of cable must be added. The repaired
bight, or bights, is lowered to the sea floor using a North Atlantic Slips preferably the
alternative method. The vehicle cuts the lowering line away and proceeds to re-bury the ocean
cable using its jetting nozzle as shown in figure B.4.3(e). It may require several runs along the
cable to bury it to the required depth, depending on bottom type.
To improve navigation while working on the repair site, prior to the deployment of the vehicle
the cable ship can lay and survey in a net of acoustic transponders covering the area in which
the fault is located. The vehicle can then be navigated using these instead of the shipboard
vehicle locator. This has the advantage of not requiring the cable ship's position to be
accurately known continuously and allows the cable ship to move more freely during the
operation. The cable ship can also use the transponder net for its own navigation.
Page A24
B.5 Notes on ROV Information.
1. The information presented was gathered from a variety of sources. Information from one
source often differs in some areas from another source. Where these difference occur and it was
not possible to ascertain which is correct, they have been left as is.
2. The information on the operation of cable repair ROVs came from the original SCARAB ROV.
Detailed information on the operation of later ROVs was not found, but the basics of the
operations, based on the limited information available, are still as for the original SCARAB,
though sensors and vehicle quietening, and analysis equipment have undergone continuous
improvements.

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3.1 Fault Location. 11

4. Jointing and Splicing Ocean Cables. 21

4.2.3.3 Jointing Large Electrical Conductors. 49

A. Electromagnetic Field Around Ocean Cables. A1

B. Cable Repair ROVs. A7

2.2.3.3.2(a) Search method. 5

2.2.3.3.4(a) Triangulation cable survey method. 7

3.1.2.2(a) Diagram of loop back system in repeaters. 13

3.1.3.1(a) Trailed electrode ocean cable and fault location method. 14

3.1.3.1(b) Towed induction coil ocean cable and fault location 15

4.2.2.2.1.2(a) Swaging sleeve onto conductors. 22

4.2.2.2.2.1(a) Portable brazing machine. 23

4.2.2.2.2.1(b) Circuit diagram - portable brazing machine. 24

4.2.2.2.2.2(a) Arrangement for brazing central conductor. 25

4.2.2.2.2.2(b) Arrangement for tinning one end of a stranded or 25

4.2.2.2.2.2(c) Arrangement for welding mild steel cores of 26

4.2.2.2.2.2(d) Arrangement for brazing ferrule on mild steel core 26

4.2.2.2.2.2(e) Arrangement for burning through high-tensile steel 27

4.2.2.2.3.1(a) Swaging press for jointing center strength member. 28

4.2.2.2.3.2(a) Steps in swaging ferrule on center strength member 29

4.2.2.3.1(a) Injection molding machine, spring feed type, single 30

4.2.2.3.1(b) Injection molding machine, spring feed type, shown 31

4.2.2.3.1(c) Pneumatically driven feed molding machine with 32

4.2.2.3.1(d) Basic components of air driven injection molding 33

4.2.2.3.1(e) Injection machine mold for quad cable ( WECo type ). 34

4.2.2.3.1(f) Injection machine mold for dielectric of coaxial cable 35

4.2.2.4.1.1(a) Transformer unit for brazing return tapes. 38

4.2.2.4.2.1(a) Cold pressure welding tool for return tapes. 39

4.2.2.5.1(a) Fusion splicer for UC/UJ technology ( Universal 40

4.2.2.6.1(a) Portable X-ray machine. 41

4.2.2.6.1(b) Cable clamp on X-ray machine exposure head. 42

4.2.2.6.1(c) X-ray camera type 13 M. III for UC/UJ technology 42

4.2.3.2.1(a) Joint on 0.051/0.180 conductor. 44

4.2.3.2.3(a) Arrangement for cutting quads and conductors to 46

4.2.3.2.3(b) Arrangement of jointing table for multi-conductor 48

4.2.3.3.3(a) Preparation of coaxial cable end for jointing. 51

4.2.3.3.3(b) Joining center conductors of coaxial ocean cable. 53

4.2.3.3.3(c) Arrangement of jointing table for coaxial ocean cables. 54

4.2.3.3.3(d) Joining multiple helically applied return tapes. 56

4.2.3.3.3(e) Joining single longitudinal return tapes. 58

4.2.3.3.3(f) Sheath restoration. 60

4.2.3.4.3(a) Basic components of Universal Jointing Kit. 62

4.2.3.4.3(b) Universal Joint ready for overmolding to restore 63

4.2.3.4.3(c) Completed Universal Joint after insulation restored 64

4.2.3.4.3(d) Deep sea cable splice. 65

4.2.3.4.3(e) Armored cable splice ( Alcatel-Lucent ). 65

4.3.1.2(a) Splicing tool for overlaid splice ( Two required, one 67

4.3.1.3(a) Preparation of cable for splicing. 69

4.3.1.3(b) Preparation of cores for jointing. 69

4.3.1.3(c) Jointing core. 71

4.3.1.3(d) Rewinding armor bedding over core. 71

4.3.1.3(e) Rewinding short end armor wires. 73

4.3.1.3(f) Short end armor wires rewound over core. 73

4.3.1.3(g) Rewinding long end armor wires. 75

4.3.1.3(h) Long end armor wires rewound over short end. 75

4.3.1.3(i) Application of outer servings. 77