IMPLEMENTATION OF CABLE HEAD REMOTE SWITCH UNIT TO INCREASE EFFICIENCY AND PRODUCTIVITY OF ONBOARD TESTING IN THE ABSENCE OF LAND INSTALLATIONS
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1 IMPLEMENTATION OF CABLE HEAD REMOTE SWITCH UNIT TO INCREASE EFFICIENCY AND PRODUCTIVITY OF ONBOARD TESTING IN THE ABSENCE OF LAND INSTALLATIONS Stephen Coy, Jon Elliott (Alcatel-Lucent Submarine Networks) Alcatel-Lucent Submarine Networks Ltd, Christchurch Way, Greenwich. SE10 0AG. UK Abstract: This paper summarises standard methods of lay watch keeping whilst no land cable or terminal equipment is present, an increasingly common challenge when implementing cable systems today. It also describes the recent development of equipment and facilities to automate the procedure. Advantages of the new system are discussed, a recent deployment evaluated and future development of the equipment considered. 1 INTRODUCTION Insulation Resistance (IR) testing is an essential procedure when deploying a submarine cable system. An IR test assesses the insulation quality of the cable and makes it possible to determine any damage to the cable. If the integrity of the cable s insulation were compromised it would allow the power-feeding conductor to be exposed to seawater, causing a shunt fault (a current leakage path to a seawater ground, where there may be no break in the power conductor). Figure 1 shows a section of damaged Light Weight Protected (LWP) cable that would cause a shunt fault. Figure 1 : A section of damaged LWP cable Shunt faults are caused by three main factors: Fishing and Ships Fishing gear Anchors Manufacturing flaws in the cable Insulation defects Joint faults Repeater termination faults Natural Forces Volcanic activity Ocean currents and chaffing Rock slides Ice scouring Ice rafting on the shoreline. A powered submarine cable system will require frequent IR tests conducted from the cable vessel during installation. This is as a result of the introduction of joints and possibly branching units (BU) along the line of the cable. The cable will be tested before and after the integration of a joint or branching unit in order to check that electrical integrity has been maintained. Typically these tests are initiated by the cable vessel requesting an Open Circuit to be placed on the shore end cable head. Copyright 2010 SubOptic Page 1 of 5
2 Once the test is complete another request will be made by the vessel to return the cable head to a Short Circuit configuration. This will generally be actioned on the Power Feed Equipment (PFE) by personnel located in the terminal station. The duty of these personnel located at the shore end is referred to as Lay Watch Keeping. In some cases no terminal station, PFE or land cable exists and the submarine cable head must be temporarily terminated in an enclosure mounted in the beach manhole. To change the configuration of the cable head in this arrangement involves manual intervention, leading to high risks to the safety of personnel, as well as significant impacts to time and thus, cost. It has been clearly identified that an automated, efficient and cost effective solution would be beneficial. 2 CURRENT METHODS OF BEACH MANHOLE LAY WATCH KEEPING The original method of lay watch keeping, where no land installation works had been completed, requires, as a minimum, a team of two trained and certified engineers to be on standby during the entire cable lay procedure. When an IR test was required by the vessel the engineers would need to be contacted and power safety messages (PSM) exchanged before entering the manhole. They would then have to manually remove the earth connection to the cable conductor, thus creating an open circuit. This is necessary to prevent the risk of electrical hazard to the engineers in the beach manhole. Other safety procedures must also be adhered to such as working in confined spaces (gas testing). Whilst this procedure works successfully it also has many drawbacks: Loss of Productivity This could be caused by communication issues between the vessel and the engineers e.g. engineers cannot be contacted; a delay in transmission of the PSMs; and time to prepare the beach manhole for a safe working environment. Engineers will not be able to work in the evening due to inadequate light, meaning that tests can only commence in the morning. Financial Costs (for Vessel and Land Based Personnel) Due to the loss in the productivity of the vessel, the overall cost of a project can increase. Vessel procedures are unnecessarily lengthened and therefore operational costs increased. A cable ship can typically cost 100,000 USD per day to function, so any unnecessary delays will have adverse financial implications. The use of two engineers for 24 hour standby is not cost effective, as they are only required when the vessel personnel needs to perform a test. Health and Safety There is a high risk to personnel when entering the beach manhole due to the possibility of contact with live high voltage cable as a result of poor communication between the lay watch keeper and the cable ship personnel. Working in confined spaces also has health and safety implications. 3 SOLUTION TO AUTOMATE BEACH MANHOLE LAY WATCH KEEPING The 'Cable Head Remote Switch unit' is designed to enable a cable-laying vessel to remotely control the configuration of the shore end cable head without manual intervention. The unit is connected to the cable head (power-feed conductor) and the armour wire anchor clamp in the beach manhole. The armour wire anchor clamp is the common ground point. The unit consists of two switchable modules and is powered by two 12V batteries in parallel. Both the unit and batteries are secured within water resistant cases to prevent moisture ingress. The setup arrangement within the beach manhole is shown in Figure 2. Copyright 2010 SubOptic Page 2 of 5
3 Figure 2 : Schematic of Beach Manhole Layout with Cable Head Remote Switching Unit installed The primary module is a GSM switch that has integrated inputs and outputs to control a high voltage relay. It is the relay that allows the cable head to be switched between open circuit and short circuit. The GSM switch is capable of receiving commands via SMS messages, to control the activity of the remote switch unit. Once the unit has carried out the command, the GSM module will return an SMS message to the originator to confirm the request was accomplished successfully. However, as a vessel is out of range of GSM signals the majority of the time, it must send the command instruction through an alternative consistently reliable medium. via the onboard IT system was considered the most suitable bidirectional form of communication. The use of a two way SMS to gateway was implemented to convert the ship s command to an SMS message, which is then forwarded to the unit located in the beach manhole. The return SMS message from the unit is sent to the gateway, which is then converted back to format and delivered to the ship s mailbox as confirmation. An overview of this process is displayed in Figure 3. Figure 3 : Interaction between Cable Ship, SMS Gateway and Cable Head Remote Switching Unit Copyright 2010 SubOptic Page 3 of 5
4 In addition to the ability to send direct commands to the unit, the controller on the vessel can also send signals to display the remaining battery charge of the device in the beach manhole, alerting crew on the ground in advance to charge the battery units. In a recent deployment, the unit was still operational after five months of being installed in the beach manhole. The internal architecture of the remote unit is shown in Figure 4. Figure 4 : Components Within Remote Unit The second module is an UHF control unit, made up of a receiver and a transmitter. The receiver also has integrated input and outputs that control the high voltage relay. The UHF method would be considered as contingency if the GSM module was deemed to fail. It would require the presence of trained personnel to enter the beach manhole in the initial instance, to toggle the unit from GSM to UHF mode. However, once in UHF mode there would be no reason to re-enter the beach manhole as a separate remote control transmitter (kept by the lay watch personnel) can control the unit within a 15 metre range. Even though the beach manhole will be safe and secure, the cable vessel would still require PSM exchange with the land based personnel in order to ensure that the power is not on the cable when switching occurs. The UHF capabilities of the device are intended as back up in the case of SMS failure, but still provide benefits of isolating the lay watch keeping team from the beach manhole and any safety issues associated with entering the beach manhole in order to change the status of the cable end. One final piece of hardware is required to make the unit function; an external GSM aerial. Beach manholes are often located in remote areas when it comes to GSM reception. To improve reception, an external aerial can be mounted on a suitable pole either installed adjacent the manhole or erected onto a convenient structure such as a nearby building or street lamp. It is also worthwhile contacting the local GSM companies to establish the locations of the local GSM transmitters so the aerial can be aligned in the direction of the nearest cell. If the GSM signal is too low for the receiver to operate, then the UHF remote control may be brought into play. 4 ADVANTAGES OF THE NEW PROCEDURE With the implementation of this process a dedicated team on standby at the shore end is no longer required. The hazardous risks associated with entering confined spaces and high voltages are eliminated. After the initial installation of the unit in the beach manhole, the shipboard personnel have complete control over the configuration of the cable end. This gives the shipboard personnel the flexibility to commence an IR test at any convenient time. It also cuts costs of providing trained personnel to be posted on standby on the shore for potentially long periods. Power safety between the ship and the shore is no longer an issue, as the ship s Power Safety Officer (PSO) will always be accountable. The saving in productivity can be very substantial when the ship s PSM procedure requests that hard copies are sent, which causes inconvenience for the land-based team (access to fax or facilities). In such instances hours can be saved with each IR test. Copyright 2010 SubOptic Page 4 of 5
5 5 IN SERVICE APPLICATION This solution was recently used most effectively during the installation of a submarine fibre optic telecommunications cable between the UK and the west coast of Africa. The system design required the integration of no less than 16 Branching Units. The Cable Head Remote Switch unit was located in the UK beach manhole at the start of the installation in the north. Whilst the ship was off the coast of Africa, it was able to control the configuration of the cable end in the UK, performing the necessary IR tests without any secondary intervention. The procedure allowed the ship to be self sufficient and it was estimated to have saved 5-6 operational days during the lay. This amounted to an approximate saving of more than half a million dollars in ship utilisation alone. 6 FUTURE DEVELOPMENTS Further development of the solution has already commenced to keep the product in line with contemporary practises, while improving efficiency and reliability during lengthy operations. Changes to the design have included: Reducing the size of the unit. Making it more manageable to handle and install. Increasing the battery capacity. The unit can now accommodate four battery units for extended service life. The introduction of two High Voltage (HV) inputs, one normally open circuit and the other normally closed circuit. The configuration of the cable end can be left in the appropriate status on installation. The shipboard personnel have the ability to send a command to verify these conditions. 7 CONCLUSION The introduction of the Cable Head Remote Switch Unit on a recently installed UK to West Africa system proved successful, increasing efficiency in the IR test procedures and overall productivity of the lay. With continued development and testing on site, the unit has been confidently deployed in other system installations. Copyright 2010 SubOptic Page 5 of 5
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