Water Blocking in Under Water Cables Tendencies in Realization

Dr. Uwe Rudorf, LEONI Kabel GmbH, Germany The penetration of water into cable is one of the most unlike things in the using of under water cables. Therefore cables can be designed for longitudinal and/or transversal water blocking. In every case transversal water blocking is a must for the cable design.

Picture 1 Water transmission directions into a cable

Transversal water blocking for cables Transversal water blocking design will be realized for cables, laid permanently in the sea floor in the cable mostly will be included additional metal or plastic wrapping materials. for flexible cables by using of special sheathing materials with very small diffusion factors. More detailed information about evaluation of suitable water blocking materials for flexible cables are published in [1], [2], [3]. Longitudinal water blocking in cables In the following, I will describe some of the different technologies for longitudinal water blocking in cables. Longitudinally water blocking is one of the special issues of cables, used in humid atmosphere or in water regions to protect the water transmission inside the cable in case of damaged cable sheath. Mostly water blocking in cables is suitable for Undersea cables Towing cables Outside installation cables on vessels, especially submarines and ROVs.

For undersea cables the water blocking characteristics are significant for the safe and log-term transmission of datas. In case of damaged cable mostly a repair in impossible or possible with very high costs only. For towing cables and ROVs water blocking helps to secure the underwater equipment from damage by water penetration. For cables, installed outside of submarines water blocking prevent the water penetration in installed equipment. If the cables are installed thru the pressure hull, the water blocking in the cable can prevent the water penetration into the submarine and therefore secure the life of people. Water Blocking Materials and Cable Designs Water blocking must be realized by prevention of water flow inside the cable and between the cable elements. The free space inside the cable must be filled during the manufacturing process of the cable completely with the water blocking material or in case of water penetration must be start the blocking process.

Picture 2 Water penetration into the cable

The water blocking feature may be realized by using of different technical methods: 1. soft rubber material 2. self-fixing jelly 3. liquid jelly 4. dry materials, swelling in case of water contact. In the following will be presented the materials with their plusses and minuses, demonstrated on different cable designs. 1. 2. 3. 4. Hard water blocking compound Self-fixing jelly Liquid jelly Dry materials, swelling in case of water contact

Standards for longitudinally water blocked cables Here will be shown as samples the Standard MIL-DTL-24643B CABLES AND CORDS, ELECTRIC, LOW SMOKE, FOR SHIPBOARD USE, GENERAL SPECIFICATION FOR 2

and the new German military standard VG 95218 part 29 Electrical cables and insulated wires Part 29: Cables, longitudinal water tight, transversal water tight, halogen free, low fire hazard, detail specification . The MIL-DTL-24643B contains requirements for the water penetration volume, coming from the soft rubber material filling and the problems to fill out all small parts of a cable with this material: Cross section of the cable (circular mills / ~mm)
Less than 9.001 / less than 4,6 9.001 to 15.000 / 4,6 to 7,6 15.001 to 25.000 / 7,6 to 12,7 25.001 to 50.000 / 12,7 to 25,3 50.001 to 100.000 / 25,3 to 50,7 100.001 to 200.000 / 50,7 to 101,3 200.001 to 500.000 / 101,3 to 253,3 500.001 to 800.000 / 253,3 to 405,3 Larger than 800.001 / larger than 405,3

Maximum allowed water penetration volume within 6 hours (cubic inch / ~cm)
4 / 65,5 5 / 81,9 6 / 98,3 7 / 114,7 8 / 131,1 10 / 163,9 11 / 180,3 12 / 196,6 13 / 213,0

Table 1 Maximum water penetration volume, allowed by MIL-DTL-24643B

The standard VG 95218 part 29 contains water blocked cables with different designs. The long time existing design type A (according to described design (1)) is made by using of soft rubber filling material. This cable is mainly used for sonar system cables, which must me vulcanized during harnessing process. The new type D is designed by using water swelling tapes and strings and completely water blocked including the single cores, the types B, C, E and F are particularly water blocked (no blocked cores). The water blocking characteristics for the type D are very high:
5.2.24.1 Longitudinal water tightness Water pressure: (6,1 0,3) MPa Type A: max. permissible water flow out quantity per 15 minutes: 5 drops Type B, C, D, E and F Deviating from the generic specification is specified in such a way the permissible water flow out quantity related to the test duration that during the first 60 minutes of max. 50 drops, altogether max. 100 drops and in the last 60 minutes no drops to flow out shall be allowed. Type A and D: core ends shall be open. Type B, C, D, E and F: Core ends shall be closed. Table 2 Part from standard VG 95218 part 29

For 24 hours as seen allowed for the type A 480 drops, for the type D only 150 drops only in the beginning of the water blocking process. The standard contains in the type line D at the moment 7 different cable types with a cross section of 0,75 mm and 1,5 mm. These cables according to VG 95218 part 29 are developed from water blocking cables with Polyurethane sheath. The experience in these cables at LEONI exists for more than 10 years. These cables are installed on submarines for Germany, South Africa, Greece, Turkey, Israel.

The new VG-design contains only halogen free materials. These cables will be installed into Submarines for Germany, Portugal and Israel. Also it is suitable for new projects. Also is a new design existing for cables with bigger cross section up to 4 x 50 mm. Mainly for fiber optic telecommunication cables are existing standards with different requirements for using liquid jelly filling compounds. Realized solutions for longitudinal water blocked cables There are existing different technical possibilities to realize the longitudinal water blocking characteristic in a cable. The blocking will be done by using more or less hard materials, which fill out continuously from the manufacturing of the cables all geometrical space inside the sheath besides the cable components like wires, insulation or armouring. On the other hand is there the possibility to use dry materials inside the cable, which will extract a jelly in case of contact with water. In the following will be demonstrated the different kinds of longitudinal water blocking in cables. The Picture 3 shows an used hard water blocking filled compound from EPR rubber material. Other similar materials also suitable. This cable design is suitable for the standard type VG 95218 part 29 A (see Table 2).

Cable sheath Core insulation

Copper wires

Hard filling compounds

Picture 3 Cable with hard water blocking compound

The main advantages of this design are Compact design Cable not compressible The main disadvantages of this design are Only suitable for single copper wires or separated multi stranded wires, because all water blocking materials must have a complete geometrical contact around all construction elements of the cable The valleys in the cables design can not be filled (blocked) completely (see also Picture 7). Not suitable for fine stranded electrical wires, because of problems to block such a wire design

Not suitable for braids in the cable design, because it is nearly impossible to fill all valleys and crossing points in the braid (see Picture 4) Permanent dropping of water out from the open end of the cable that is the reason for the allowed water penetration volume, mentioned in the standard MIL-DTL24643B (see Table 1) In case of bending the cable the hard filling compound will lose the close contact to the copper wires and will stay in this position. The water can penetrate thru these open spaces (see Picture 5)

Valleys

Crossing points of the braid

Picture 4 Copper braid of a cable

Bending marks

Picture 5 Cutting from Picture 3 with bending marks

The Picture 6 shows a cable component with included water blocking self-fixing jelly around the cores. The single copper wires in this design are not water blocked.

Cable sheath Core insulation Copper wire

Self-fixing filling compound

Picture 6 Cable part with self-fixing water blocking compound

The main advantages of this design are Compact design Cable not compressible High flexibility of the cable In case of bending the cable the hard filling compound will keep the contact to the water blocked construction elements and will stay in this position. (see Picture 5) The main disadvantages of this design are Not suitable for stranded copper wires, because all water blocking materials must have a complete geometrical contact around all construction elements of the cable The valleys in the cables design can not be filled (blocked) completely (see also Picture 7). Not suitable for fine stranded electrical wires, because of problems to block such a wire design Not suitable for braids in the cable design, because it is nearly impossible to fill all valleys and crossing points in the braid (see Picture 4) Permanent dropping of water out from the open end of the cable that is the reason for the allowed water penetration volume, mentioned in the standard MIL-DTL24643B (see Table 1)

Space which can not be filled with hard and self-fixing compound (valleys)

Picture 7 Cutting from Picture 6 valleys in the cable between the cores

Also suitable for the realization of water blocking characteristics is a soft jelly.

Picture 8 Cable with soft jelly filling compound

The main advantages of this design are Compact design Cable not compressible High flexibility of the cable The soft filling compound will flow nearly completely into the valleys of the cable design Suitable also for stranded copper wires, because all water blocking materials must have a complete geometrical contact around all construction elements of the cable In case of bending the cable the soft filling compound will keep the close contact to the water blocked construction elements and will stay in this position. (see Picture 5) The main disadvantages of this design are The valleys in the cables design can not be filled (blocked) absolute completely (see also Picture 7). Not suitable for braids in the cable design, because it is nearly impossible to fill all valleys and crossing points in the braid (see Picture 4) In case of high longitudinal pressure the soft jelly flow out from the cable. 7

Permanent dropping of water out from the open end of the cable that is the reason for the allowed water penetration volume, mentioned in the standard MIL-DTL24643B (see Table 1) In case of higher temperatures and motion of the cable the soft jelly permanently will flow out from the cable.

An alternative solution for water blocking design is the using of water swelling materials, fixed in tapes, binders (fillers) and strings (see Picture 9). These water swelling materials will form a very soft jelly in the place, where the water penetrate into the cable. All places without water contact are staying dry. This cable design is suitable for the standard type VG 95218 part 29 B-F (see Table 2).
Cable sheath

Core insulation Copper wires

Water swelling string Water swelling fillers Water swelling tape Copper braid Picture 9 Cable with water swelling fillers and strings

The main advantages of this design are Cable absolutely water blocked (tested up to a pressure of 100 bars) Design suitable also for fine stranded wires High flexibility of the cable No permanent jelly flow out of the cable Cables are easy to harness Wire braid also can be water blocked The main disadvantages of this design are Cable not compact Cable compressible (special design of feed trough for connectors necessary) The cable according to the design with the water swelling materials are completely fulfil the requirements of the new German military standard VG 95218 part 29 (see Table 2). Realization of the water blocking test The tests were made in a special pressure tank, where one open end of the cable is located in the tank with the pressure of 63 bars and the second open end is located outside (see Picture 10).

Picture 10 Test equipment for longitudinal water blocking tests

From the beginning of the test up to the end after 24 hours no one drop was flowing out from the cable. The penetration dept of water into the cables depends from the design and the number of cores between approx. 150 mm and 700 mm (see Picture 11 as a sample).

Picture 11 Sample of a tested water blocked 3-core cable after 24 hours of water penetration

LEONI has the experience of more than 10 years with this design of water blocking cables with water swelling materials, mainly used for outboard installation cables on submarines. There were manufactured during this time more than 60 different cable designs. These cables are installed on all German submarines type 212 and on all submarines type 209 and 214, produced by the German shipyards since 1996. Also a lot spare part cables were delivered worldwide. A test designs with a combination of water swelling materials and a filling compound was made for cables with bigger cross section (here 2 x 10 mm) to have a more compact design (see Picture 12) than with an only implementation of water swelling materials into the valleys.

Picture 12 Test cable design with a combination of water swelling materials and a filling compound

LEONI also is able to manufacture cables with self-fixing and soft water blocking materials. These materials in use since more than 15 years for a lot of different designs. Conclusions For many cables, used or installed in water, the water blocking characteristics one of the main issues. Therefore it is to separate between transversal water blocking (thru the sheath) and longitudinal water blocking (in longitudinal direction along the cable). For transversal water blocking evaluation exist a lot of references. For longitudinal water blocking exists several technical solutions. Depending from the installation and using type of the cable it can be realized by hard filling compounds, selffixing jelly, soft jelly or try materials, swelling in case of water contact.

References [1] Cindy Koldrack, Uwe Rudorf Influence of sea water on mechanical parameters of plastic materials, especially cable sheathing materials See: Conference material UDT Underwater Defence Technology Europe 2007; 5.-7. June 2007; Napoli (CD) [2] Rudorf, Uwe Rckschlsse von Isolationswiderstandsmessungen an Unterwasserkabeln auf die Lebensdauer der Kabel (Conclusions from the measurement of the insulation resistance of underwater cables to lifetime of the cables) See: Schiffbauforschung 4/2003 [3] Mathias Paschen, Cindy Koldrack, Uwe Rudorf Untersuchungen zum Langzeitverhalten von Unterwasserkabeln (Evaluations of longterm behaviour of underwater cables) See: Shaker Verlag, Aachen 2006

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