Development of Fatigue-Less Umbilical Cable for Full Ocean Depth 12000m

Katsuya Sakamoto1, Yoshihiro Fujimoto1, Hiroyuki Osawa2

Marine Cable Development Section Engineering Dept. Telecommunications Company The Furukawa Electric Co., LTD Ichihara, Chiba 290-8555, Japan +81-436-42-1644 email address katsuyas@ch.furukawa.co.jp 2 Advanced Underwater Vehicle R and D Group, Marine Technology Research and Development Program Japan Agency for Marine-Earth and Science Technology (JAMSTEC) Yokosuka 237-0061, Japan +81-46-867-9384 email address osawah@jamstec.go.jp
1

Abstract
We have developed the fatigue-less umbilical cable for full ocean depth 12000m. It enables us to use at ease even under the hard condition such as the highest water pressure in the world ocean by means of the unique strength members combined with the structure of completely balanced water pressure. As the special strength member, we use the new FRP rod. The characteristic of this FRP rod is as follows. It enables us to make minimum bending radius small compared with the other FRP rod, for instance, glass FRP and Kevlar FRP. And the tensile strength of this new FRP rod hardly doesnt deteriorate against repeated lateral compressive force, repeated bending and repeated twisting of the cable. We had good results of fatigue estimation of the cable under the condition of not only atmospheric pressure but also water pressure more than 120MPa.

that, a fatigue-less umbilical cable has wanted recently. Accordingly, we investigated thoroughly the cause of the deterioration of the tensile strength of these cables. As a result of that, we found that the deterioration was caused by a damage of Kevlar fibers in a molecular structure. In this paper, we have newly developed the fatigue-less umbilical cable by using the special FRP rod and making the water pressure for each rod balanced completely. We manufactured two kinds of trial cables for the secondary cable which is between launcher and ROV, and made a comparative study of fatigue estimation under the condition of air pressure and the highest water pressure.

Support Vessel Launcher

Keywords: Umbilical cable; Marine cable; Tether cable; Towed

cable; Deep sea; KAIKO; ROV; FRP rod; Water pressure; lateral compressive force; Repeated bending; Repeated twisting; Fatigueless.

1. Introduction
Recently, a scientific research in the ocean gets more and more important. In a survey of the deep ocean more than 6500m, remotely operation vehicle (ROV) is often used. In Japan, as the cable used in the ocean depth 12000m, Japan Agency for Marine-Earth Science and Technology (JAMSTEC) has already the umbilical cable of KAIKO system. This system has two cables, the primary cable and the secondary cable. One is the tether cable between support vessel and launcher, whose length is 12500m the other is the tether cable between launcher and ROV, whose length is 250m. These cables have the strength members composed of Kevlar fibers. Its structure is FRP rod type and braided net type. However, it is know that the tensile strength of these cables deteriorate gradually due to fatigue given by water pressure, lateral compressive force from the sheave and so on. In the primary cable, now, its tensile strength has deteriorated until about 70% compared with unused cable since it was manufactured in 2000. Therefore, recently we have inspected its broken tensile strength once a year. Generally, it is thought that marine tether or towed cable used under the hard condition such as deep sea is expendable article. However, in the unique cable such as primary cable, manufacturing and maintaining it cost a large amount of money, much time and great care. By reason of

Umbilical Cable Vehicle Figure 1. Marine Survey ROV System

2. Cable Structure
General requirements for the secondary cable used in the deep sea are as follows. - It must be proof against the highest water pressure of 120MPa. - Its specific gravity must be almost the same with sea water. - It must be fatigue-less against the motion of the cable under the condition of water pressure. Figure 2 shows the cross-sectional structure of fatigue-less opticalpower line composite umbilical cable.

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Power Line Earth Line

Strength Member of FRP Rod

Polyester Braided-net Optical Fiber Unit

Figure 3. Cracks in some mono-fibers in the K-FRP

Figure 2. Cross-Sectional Structure of Fatigue-less Umbilical Cable

3.3 Durability against Lateral Compressive Force

3.3.1 Experimental Method The test of Durability against the lateral compressive force was performed as shown in Figure 4. The two kinds of the FRP samples in the Table 1 were used. Test conditions are as follows. - Lateral pressure is 1470N per FRP length 22mm. It was determined by considering the operation of the system. - Compressive velocity is 10mm per minute. - Times per cycle are about 7 seconds. The kept times at the maximum point is nothing. - Repeated number is 100 and 1000 times. After that, a deformation of the FRP rod and the tensile strength ratio were examined. Repeated P Lateral

3. Design of Strength Member

3.1 Basic Properties of FRP Rod
In the shallow ocean, as the strength member for the umbilical cable metallic materials are often used. However, in the deep ocean, high strength fiber is used for the purpose of making the weight in the sea water light. Generally, Kevlar fiber is well known. We have developed a new FRP rod, which is jacketed by polyamide or polyolefin resin, composed of copolymer type Aramid fiber to make the fatigue-less umbilical cable come true. The new FRP rod shows an excellent performance in comparison with Kevlar FRP rod. Table 1 shows making a comparison of the basic properties between the new FRP (T-FRP) and Kevlar FRP (K-FRP) rod, which have the same FRP diameter 2.5mm and the same thickness of 0.35mm. TFRP has a unique characteristic that the minimum bending diameter is very small compared with K-FRP. Table 1. Basic Properties of 2.5mm FRP Rod
Item Tensile strength Youngs modulus Minimum bending diameter K-FRP T-FRP

FRP Rod Sample

[MPa] [MPa] [mm]

1558 68100 63

1676 47599 26 Plate length = 22 Figure 4. Lateral Pressure Test Apparatus 3.3.2 Results of Lateral Pressure Test The test results of the lateral pressure cycle are shown in Figure 5. A solid line shows the tensile strength ratio for the original FRP, and a dotted line shows the deformation of the FRP due to the compressive force. An extent of the deformation is determined by the following formula, we call it non-circularity ratio.

3.2 Durability against Water Pressure Cycle

3.2.1 Experimental Method We performed the water pressure cycle test of the FRP samples shown in the Table 1. Test conditions are as follows. - Maximum water pressure is 119.6MPa. - About 10 minutes per cycle is kept at the 119.6MPa. It takes about 30 minutes per cycle. - The repeated number is 20 and 200 times. After that, tensile strength ratio for the original FRP, for which every load wasnt given at all, was estimated. 3.2.2 Results of Water Pressure Cycle Test The deterioration of the tensile strength for the T-FRP scarcely occurred, but for the K-FRP, the tensile strength ratio has gradually deteriorated to about 85% after 20 cycles, and to about 70% after 200 cycles. Close observation of the FRP cross-section showed that there were cracks in some mono-fibers for the K-FRP as shown in Figure 3.

R=

DL DS 100 DL + DS

(1)

Where R is the non-circularity ratio, DL is the long diameter, and DS is the short diameter. In the K-FRP, large deformation occurred, and the tensile strength deteriorated to about 79% after 100 times, and to about 54% after 1000 times. However, in the T-FRP, the deformation was small, and the deterioration of the tensile strength scarcely occurred.

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Tensile Strength Ratio [%]

20 15 10 5 0 200 400 600 800 0 1000

Non-circularity Ratio [%]

4.4 Initial Performance of Trial Cable

Both of trial cables were manufactured using inner sheath core of the same size, which diameter is 19.3mm. As outer jacket on the strength member, which are the FRP rods shown in the Table 2. polyester braided-net was used. Cable diameter is 29mm and the specific gravity is 1.3 or less. Table 3 shows the initial mechanical characteristics of these trial cables. K or T represents that the strength member is the K-FRP or the T-FRP respectively. Table 3. Initial Mechanical Characteristics of Trial Cables
Item Tensile Broken Strength Elongation at tension of 10[kN] Elongation at Breaking Point [kN] [%] [%] K 108 0.3 2.8 T 114 0.5 4.2

80 60 40 20 0
Lateral Pressure Cycle Tensile Strength Ratio K-FRP Non-circularity Ratio K-FRP

Tensile Strength Ratio T-FRP Non-circularity Ratio T-FRP

Figure 5. Results of Lateral Pressure Cycle Test

4. Trial Cable Design

4.1 Requirements of Trial Cables
In this paper, we describe the development of the secondary cable between the Launcher and the ROV for full ocean depth 12000m. We must pay attention to its requirements because it is different from that of the primary cable between the support vessel and the Launcher. In the secondary cable, the cable tension is almost free when the ROV operates separate from the launcher. However, the motion is very complicated and hard. For example, under the highest water pressure, rolling in a reel, paying out the cable, bending, pulling, and twisting are given repeatedly. Taking all things into consideration, the most important requirement of the trial cable is that the damage to the FRP given by the operation of the ROV must be kept a minimum even if the cable is used in the deepest sea in the world. - Stress to each FRP rod given by the water pressure must be isotropic. - Water pressure must not prevent the motion of each FRP.

5. Fatigue Experiments
In order to show the superiority of the trial cable T, four fatigue experiments were performed under the same condition for the trial cables K and T. At first, these tests were performed in the water pressure of 123MPa. For the purpose of these special experiments, we have developed the fatigue experimental facilities which can be used under the condition of 123MPa. Especially, the bending test and the twisting test were also performed under the condition of the atmospheric pressure for the purpose of investigating the influence of the water pressure.

5.1 Mechanical Characteristics in 123MPa

5.1.1 Experimental Methods It was supposed that the considerable motion of the cable when the ROV operates. Table 4 shows the test condition in the water pressure 123MPa. After that, any numbers of the FRP rods were picked up, and the tensile strength ratio was measured. Figure 6 shows the experimental apparatus of the S-Bending test. Other tests were also performed in the similar way by changing the S-bending unit into the other unit. Table 4. Test Conditions in 123MPa
Item Pull and Relax Twisting S-Bending U-Bending Tension [N] 3920 3920 3920 3920 Cable Disposition Other Load Straight Line Straight Line 45 [degree/m] S-Shape R=150[mm] U-Shape R=150[mm] Repeat Times 1000 1000 1000 1000

4.2 FRP Rods in Trial Cables

We manufactured two kinds of trial cables in order to show that the T-FRP rod was superior to the K-FRP rod. Table 2 shows the basic properties of the FRP rod in the trial cables. These FRP were designed at the same size to make the deference of the cable performance clear. Table 2. Measured Values of FRP Rod in Trial Cables
Item FRP diameter Sheath diameter Mass Tensile strength [mm] [mm] [g/m] [MPa] K-FRP Inner 1.22 1.8 3.00 1480 75550 29 Outer 1.00 1.7 2.51 1440 76875 26 T-FRP Inner 1.24 1.8 2.98 1842 53500 14 Outer 1.01 1.7 2.65 1837 52400 12

Youngs modulus [MPa] Minimum bending [mm]

4.3

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Table 5. Measured Values of FRP Rod in Trial Cable T

Water Tank S-Bending Unit Pressure

Item FRP diameter Sheath diameter [mm] [mm] [g/m] [MPa]

T-FRP Inner 1.24 1.8 3.02 1603 55260 13 Outer 1.00 1.7 2.57 1633 49320 9

Fatigue Experimental Facilities

Mass Tensile strength

Trial Cable

Tension Equipment

Youngs modulus [MPa] Minimum bending [mm]

Figure 6. S-Bending Test in Water Pressure Tank 5.1.2 Test Results in 123MPa The test results of the fatigue experiments under the condition of the water pressure 123MPa are shown in the Figure 7. It was confirmed that the deterioration scarcely occurred in the trial cable T. For the trial cable K, as expected, the deterioration of the tensile strength is large in comparison with the trial cable T, but it is small in comparison with the results shown in the sub-subsection 3.2.2 and Figure 4. As the reasons, two facts are thought. First, the FRP diameter used in the trial cables is smaller than that used in the water pressure cycle test and the lateral pressure cycle test in the section 3. The difference relates to the stress to the internal part, which is monofiber, of the FRP rod. Secondly, the lateral pressure due to the interaction between the FRP and the sheave in the tests like Ubending and S-Bending is different from that of the lateral pressure cycle test in the section 3. The lateral pressure of the bending tests in the Table 4 is estimated at about 40%.
100. 0
Tensile Strength Ratio [%]

Test conditions of the trial cable T are shown in the Table 6. The condition of tension 9800N corresponds to the lateral pressure tested in the section 3.3.1. Table 6. Test Conditions of Trial Cable T
Item Experimental Surrounding Atmosphere and 120MPa Atmosphere and 120MPa Tension [N] 3920 9800* 3920 9800* Cable Disposition Other Load Straight Line 45 [degree/m] S-Shape R=150[mm] Repeat Times

Twisting SBending

1000 1000

*Tension 9800N is the only condition of the water pressure 120MPa.

5.2.2 Test Results For all the conditions in the Table 6, the tensile strength ratio was 99% or more. These results show that in our cable structure, the water pressure doesnt influence to the motion of the cable even if the cable is used in the deepest sea in the world.

98. 0 96. 0 94. 0 92. 0 90. 0 88. 0 86. 0 P ul land R el ax Tw i sti ng S -bendi ng U -bendi ng K -FR P T -FR P

6. Other Performances of Trial Cable T

6.1 Transmission Characteristics of Optical Fiber
For the trial cable T, a transmission loss change was monitored at the wavelength 1550nm in the middle of the fatigue tests in the section 5.2.1. For all the conditions in the Table 6, the transmission loss change of the cable was 0.02dB or less.

6.2 Extended Durability for Bending

6.2.1 Experimental Methods We have succeeded in the development of the fatigue-less umbilical cable for full ocean depth 12000m. However, it is the results verified under the condition of repeat times 1000. Therefore, it is necessary that we should show more extended durability. In the atmospheric pressure, S-Bending test of the trial cable T shown in Figure 8 were performed under the following conditions, the sheave diameter is 400mm, tension is almost free, and the repeat number is 320000 times. In the middle of the test, the transmission loss change was monitored at the wavelength 1550nm. After that, the tensile strength ratio was measured. The cable deposition of this test is different from one shown in Figure 6. Bose of the cable terminations are fixed at two sheaves respectively, and the sheaves rotate.

Figure 7. Mechanical Characteristics in 123MPa

5.2 Compared with Atmospheric Pressure

5.2.1 Experimental Methods We manufactured the other trial cable T which was composed of the other T-FRP shown in the Table 5. The mechanical characteristics of the trial cable T is almost the same as the trial cable T shown in the Table 3. In order to investigate the influence of the water pressure to the mechanical characteristics of the cable, the Twisting tests and the S-Bending tests were performed under all the same conditions except for the experimental surrounding, which is in atmospheric pressure or in the water pressure 123MPa. For the atmospheric pressure condition, the fatigue experimental facilities shown in the Figure 5 were used out of the water pressure tank.

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Trial Cable

9. Pictures of Authors
Katsuya Sakamoto The Furukawa Electric Co., LTD 6 Yawatakaigan-dori, Ichihara, Chiba 290-8555, Japan katsuyas@ch.furukawa.co.jp He was born in Oita, in 1968. He received the M.Sc. degree in theoretical physics from Shimane University, Japan in 1993. He jointed The Furukawa Electric Co., Ltd. in 1993 and has been engaged in research, development and production engineering of marine cable technology. He is now a senior engineer of marine cable development section, engineering dept., Telecommunications Company. Yoshihiro Fujimoto The Furukawa Electric Co., LTD 6 Yawatakaigan-dori, Ichihara, Chiba 290-8555, Japan

Sheave R 200 Figure 8. S-Bending Apparatus for Extended Durability 6.2.2 S-Bending Test Results of Extended Durability We had excellent results that the tensile strength ratio is 96% and over, and the transmission loss change of optical fiber is 0.1dB or less. It was showed that the deterioration due to repeated bending scarcely occurred.

7. Conclusions
We have obtained the fatigue-less secondary umbilical cable by studying a mechanism of the deterioration of the Kevlar fiber. This ideal umbilical cable can be used in the deepest sea in the world, and has the excellent characteristics of that the tensile strength scarcely deteriorates against the motion of the cable under the hard condition. By using this new FRP rod, it is expected that the fatigueless primary umbilical cable can also be realized in the near future.

y-fuji@ch.furukawa.co.jp He was born in Chiba, in 1959. He received the B.E. degree in Metal engineering from the Chiba Institute of Technology, Japan in 1983. He jointed The Furukawa Electric Co., Ltd. in 1992 and has been engaged in research, development production engineering of marine cable technology. He is now a manager of engineering dept., Telecommunications Company. Hiroyuki Osawa, Dr. Eng. Japan Agency for Marine-Earth Science and Technology 2-15 Natsushima-cyo, Yokosuka 237-0061, Japan osawah@jamstec.go.jp He was born in Tokyo, in 1963. He received the Ph.D Ocean Engineering, Nihon University JAPAN in 1996. He joined Japan Marine Science and Technology Center in 1996 and has been engaged in research, marine technology. He is now group leader advance marine technology research program, marine technology center.

8. Acknowledgments
For writing this paper, we give the special thanks to Advanced Underwater Vehicle R and D Group, Marine Technology Research and Development Program, Japan Agency for Marine-Earth Science and Technology, Aramid Product Development Section, High Performance Fibers Research and Development Department, TEIJIN TECHNO PRODUCTS LIMITED, and UBE-NITTO KASEI CO., LTD. And also, we greatly appreciate the united efforts of a number of people.

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